JP2005178069A - Method and apparatus for transfer processing of fine shape - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a method for transferring the fine shape of the surface of a die with high precision by preventing an increase in the surface viscosity of a thermoplastic resin in shaping the thermoplastic resin. <P>SOLUTION: After carbon dioxide being gas having a plasticizing effect is infiltrated in the surface layer of the molten resin 1, the fine pattern 2 of a die core 3 having the fine pattern 2 on its surface is pressed to the surface of the carbon dioxide-infiltrated molten resin 1 to be transferred to the surface of the carbon dioxide-infiltrated resin. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a fine shape transfer processing method and apparatus for transferring a fine shape pattern to a surface, and can be applied to processing of a resin workpiece such as a microfabrication part such as a microreactor.

  In general, an injection molding method is used as a method for molding a thermoplastic resin. This is because a molded product can be easily manufactured because the molten resin is filled in the mold cavity forming the shape of the molded product, and the mold temperature is kept below the solidification temperature of the resin to cool and solidify. . However, in order to keep the mold temperature below the solidification temperature of the resin, the filling and cooling of the resin proceed simultaneously, and the resin in contact with the mold at the flow front is rapidly cooled, so the clay becomes higher and lower. Since it is pressed against the mold by pressure, it is difficult to transfer a fine pattern on the mold surface with high accuracy.

Conventionally, in order to transfer a fine pattern on the mold surface with high accuracy,
1. A method of heating and cooling the mold surface by alternately flowing a heat medium and a refrigerant through the mold (Plastic Technology Vol. 34, 150 (1988)).
2. Method of heating the mold surface by high frequency induction heating before molding (US Pat. No. 4,439,492)
3. A method in which an insulating layer and a conductive layer are provided on the surface of the mold and the conductive layer is energized and heated (Plym. Eng. Sci., Vol 34 (11), 894 (1994))
4). Method of radiant heating of mold surface (Rigid resin, Vol42, (1), 48 (1996)
5). A method of providing a heat insulating layer on the mold surface and heating the mold surface with the heat of the resin (US Pat. No. 5,362,226)
Etc. are known.

  In these methods, the surface of the mold is heated to delay the cooling of the resin surface and the viscosity of the resin is lowered to increase the transfer accuracy. However, increasing the mold surface temperature tends to cause temperature unevenness in the mold, causing warping of the molded product, and distortion due to mold release unevenness. There is also a problem that the cooling of the resin is delayed and the molding cycle cannot be shortened.

  Apart from this, a method is known in which a gas body is filled in a mold cavity and a resin is injected and filled, as in Japanese Patent No. 3096904. In this method, the mold needs to have a sealed structure in order to bring the gas pressure in the mold cavity to a certain pressure state. Therefore, it is necessary to incorporate an O-ring or U-packing around the parting surface, between each plate, and around the protruding pin, which restricts the mold structure. Furthermore, a gas pressure of up to about 15 MPa is required in the cavity, and equipment for generating high-pressure gas is required.

  In addition, a method is known in which molding is performed by reducing the melt viscosity of the entire resin. For example, as disclosed in Japanese Patent No. 3218397, a method of dissolving 0.2 wt% or more of carbon dioxide in a molten resin, or as disclosed in Japanese Patent Application Laid-Open No. 2001-9882, supercritical carbon dioxide is injected. There are methods. However, any of these methods requires equipment for generating high-pressure gas as described above.

  Furthermore, a molded product that requires microfabrication for transferring a fine pattern with high accuracy is required to be smaller and thinner. In the injection molding method, it is necessary to take a large number of molds in consideration of mass productivity and cost. However, it is very difficult to make the same molding state in each cavity when the molded product is small. Further, a sprue that guides the resin to the cavity is necessary, and in the case of a small molded product, the amount of the sprue resin may be larger than that of the molded product. When the sprue can be reused, further reuse facilities are required, and when the sprue cannot be reused due to the molded product, it is discarded and the use efficiency of the resin is lowered.

In the injection molding method, flow resistance is generated by increasing the resin viscosity by cooling the resin during filling. As the thickness of the molded product decreases, the resin cooling becomes faster, so that the flow resistance increases and a high filling pressure is required. As a result, the pressure distribution inside the molded product becomes uneven, resulting in deformation of the molded product. It is known that a resin containing a gas body that produces a plasticizer effect such as AMOTEC (Asahi Molding Technology with Co2) or Mucell (US, TREXEL, registered trademark) can be filled at low pressure. However, since the gas body is volatilized from the resin, the shrinkage rate after molding becomes larger than that of normal molding, resulting in poor accuracy. Moreover, in order to contain gas, the gas equipment for generating a high pressure is needed, and an installation becomes large-scale.
U.S. Pat. No. 4,439,492 US Pat. No. 5,362,226 Patent No. 3096904 Japanese Patent No. 32189797 Japanese Patent Laid-Open No. 2001-9882 Plastic Technology Vol. 34, 150 (1988) Plym. Eng. Sci. , Vol 34 (11), 894 (1994) Rigid resin, Vol 42, (1), 48 (1996)

  Accordingly, an object of the present invention is to provide a method and an apparatus for transferring a fine shape on a mold surface with high accuracy by preventing an increase in resin surface viscosity in molding a thermoplastic resin. Further, another object of the present invention is to provide a method and an apparatus for transferring a fine shape of a mold surface with high accuracy by preventing an increase in resin surface viscosity without using a conventional large-scale equipment. Is the purpose.

  In order to solve the above-mentioned problems, the invention according to claim 1 is characterized in that after the molten resin surface is impregnated with a gas body having a plasticizing effect, the surface of the resin impregnated with the gas body is finely formed on the surface. The fine pattern transfer processing method is characterized in that the fine pattern of the transfer body having a pattern is pressurized and the fine pattern is transferred onto the surface of the resin impregnated with the gas body.

  In the invention according to claim 2, after impregnating the melted resin surface layer with a gas body having a plasticizing effect, the surface of the resin impregnated with the gas body is pressurized with a nest having a fine pattern on the surface. A fine shape transfer processing method, wherein a fine pattern is transferred to the surface of the resin impregnated with the gas body.

  In the invention according to claim 3, in the impregnation of the gas body, the gas body having a plasticizing effect is sealed by the surface of the molten resin and the nesting having a fine pattern on the surface, and the nesting is performed on the surface of the resin. 3. The fine shape transfer processing method according to claim 2, wherein the sealed gas body is pressurized by being advanced toward the surface, and the surface layer of the resin is impregnated with the gas body.

  According to a fourth aspect of the present invention, in the fine shape transfer processing method according to the second aspect, the nesting has a protrusion that surrounds the periphery of the fine pattern and protrudes from the fine pattern surface. is there.

  The invention according to claim 5 is characterized in that the molten resin is cut and processed into a predetermined molded product shape together with the operation of transferring the fine pattern by pressurizing the insert. 2. The fine shape transfer processing method according to 2.

  According to a sixth aspect of the present invention, a molten resin is sandwiched between a mold and a mold having a fine pattern on the bottom surface of the mold. Is filled with a gas body having a plasticizing effect on the resin, the mold is advanced toward the resin, the resin is cut, and then the fine pattern is applied to the resin to press the fine pattern onto the surface of the resin. A fine shape transfer processing method is characterized in that a fine pattern is transferred.

  According to a seventh aspect of the present invention, a molten resin is sandwiched between a mold and a recess that is fitted with the mold, and a fine pattern is formed on the bottom surface of the recess, and the inside of the recess of the insert Is filled with a gas body having a plasticizing effect on the resin, and then the nest is advanced toward the resin, and the resin is cut, and then the fine pattern is pressed onto the resin to be applied to the surface of the resin. A fine shape transfer processing method is characterized in that a fine pattern is transferred.

  According to an eighth aspect of the present invention, there is provided a fine shape transfer process, wherein a plurality of fine patterns are transferred by repeatedly performing the fine shape transfer processing method according to claim 2 on one molten resin surface. Is the method.

  The invention according to claim 9 connects an extruder for supplying a molten resin and a fine pattern processing apparatus for impregnating a gas body having a plasticizing effect and pressurizing and transferring a fine pattern, thereby increasing the resin supply speed. 9. The fine pattern transfer processing according to claim 8, wherein the transfer body is moved at the same speed in conjunction, and fine pattern transfer processing is performed when the resin supply speed and the transfer body movement speed are the same speed. This is a transfer processing method.

  The invention according to claim 10 pressurizes a fine pattern with a nest having a temperature adjustment function equal to or lower than the heat distortion temperature of a molten resin having a glass transition temperature or higher, and cooling the nest and the resin in that state, thereby 10. The fine shape transfer processing method according to claim 8 or 9, wherein the separation is performed.

  According to an eleventh aspect of the present invention, a gas body having a plasticizing effect is sealed with a molten resin surface and a nest having a fine pattern on the surface, and the gas body is pressurized by advancing the nest, After transferring the gas body to the surface layer to lower the melt viscosity of the resin surface layer, the pressure of the gas body is released by a pressure reducing valve, and then a fine pattern is transferred to the surface of the molten resin. It is a processing method.

  Further, the invention according to claim 12 supplies a gas body having a plasticizing effect heated to a temperature higher than the glass transition point of the resin by a heating device in the space formed by the nesting having a fine pattern on the resin surface and the surface. The gas body is pressurized by advancing the nesting, the resin surface layer is impregnated with the gas body to reduce the melt viscosity of the resin surface layer, and then the fine pattern is transferred to the surface of the resin impregnated with the gas body. This is a transfer processing method having a fine shape.

  According to a thirteenth aspect of the present invention, there is provided a means for impregnating a melted resin surface layer with a gas body having a plasticizing effect, and a transfer body having a fine pattern on the surface of the resin impregnated with the gas body. And a means for pressurizing the fine pattern.

  The invention according to claim 14 is the fine shape transfer processing apparatus according to claim 13, wherein the molten resin is supplied at the same speed as the transfer body.

  According to the first aspect of the present invention, the plastic surface is selectively plasticized by the plasticizing effect of the plastic body to cause a decrease in the solidification temperature and a decrease in the melt viscosity, and the transfer body is pressed to form a fine shape. Since the pattern is transferred, there is no foaming phenomenon that occurs when the molten resin is molded with a gas body having a plasticizing effect, and a highly accurate transfer can be obtained.

  According to the second aspect of the present invention, the plastic surface is selectively plasticized by the impregnation of the gas body having a plasticizing effect, and the resin surface is selectively reduced in solidification temperature and melt viscosity is reduced to press the nesting to form a fine shape. Since the pattern is transferred, there is no foaming phenomenon that occurs when the molten resin is molded with a gas body having a plasticizing effect, and a highly accurate transfer can be obtained.

  According to the third aspect of the present invention, the pressurization for impregnating the gas body having a plasticizing effect and the pressurization for the transfer of the fine shape pattern can be simultaneously performed. Equipment is not required.

  According to the invention described in claim 4, since the gas body having a plasticizing effect can be sealed by the projection, the mold structure is simplified.

  According to the fifth aspect of the present invention, when a molded product is manufactured by processing a resin, it can be molded by a pressing method, and therefore, unnecessary things such as a sprue are not generated unlike the injection molding method.

  According to the sixth aspect of the present invention, it is possible to simultaneously perform pressurization for transfer and formation of a molded product shape without using a large-scale facility as in the prior art. It becomes possible.

  According to the seventh aspect of the present invention, the gas body having a plasticizing effect can be sealed by the projection without using a large-scale facility as in the prior art, and the molded product can be formed only by the forward pressurization of the nest. Since it can be manufactured, the device structure is simplified.

  According to the invention described in claim 8, since a large number of molded products can be obtained with a small number of inserts, the die cost can be reduced.

  According to the ninth aspect of the present invention, since the nest is moved and molded, even if the molding tact is long, a molded product can be obtained with a small number of nests, so that the mold cost can be reduced.

  According to the invention described in claim 10, since the temperature of the nesting is low, the molding cycle can be shortened.

  According to the eleventh aspect of the present invention, since the gas body having a plasticizing effect can be discharged from the transfer surface at an arbitrary pressure or position, the transfer accuracy can be increased.

  According to the twelfth aspect of the invention, since the resin can be heated by the heat of the heated gas body having a plasticizing effect, the gas body also has a plasticizing effect on a solidified resin surface such as a sheet. Can be impregnated, and press molding or the like becomes possible.

  According to the invention described in claim 13, the resin surface is selectively lowered by the plasticizing effect by impregnation of the gas body having a plasticizing effect without using a large-scale facility as in the prior art, the melt viscosity Transfer is performed by pressurizing the transfer body and transferring a fine pattern, so that there is no foaming phenomenon that occurs when molding is performed by including a gas body having a plasticizing effect in the molten resin, so that a highly accurate transfer can be obtained. .

  According to the fourteenth aspect of the present invention, since the supply of the molten resin and the movement of the transfer body are made at the same speed, the amount of the resin at the time of molding becomes constant, and the gas body having a stable plasticizing effect is added. Pressure and pressurization of the mold insert 3 into the resin are possible.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a diagram for explaining the operation of the transfer processing apparatus according to the first embodiment of the present invention, and FIG. 2 is a view showing the temperature of the resin in each step of FIG. As shown in FIG. 1, the transfer processing apparatus includes an extruder 20 and a fine pattern processing apparatus 21. The extruder 20 flows the molten resin 1 from the nozzle 20a onto the conveying means 22 in a sheet shape and supplies it to the processing position of the fine pattern processing apparatus 21 connected to the extruder 20 (position of the resin conveying step). (1)).

  The fine pattern processing device 21 is arranged in an atmosphere of a gas body having an effect of plasticizing a resin, in this embodiment, carbon dioxide G. The fine pattern processing apparatus 21 includes means (not shown) for conveying the mold insert (transfer body) 3 such as a robot arm. This conveying means (not shown) conveys the mold insert 3 at the same speed as the supply speed of the molten resin 1 together with the cutters C attached to both side surfaces of the mold insert 3 so as to be movable back and forth. This conveyance is at the same speed at least between the position (2) in the transfer space sealing step, which will be described later, and the position (5) in the slow cooling step. Other positions may have the same speed or may not have the same speed.

  The fine pattern processing device 21 is arranged in order from the upstream side in the transport direction of the molten resin 1, the position (2) of the transfer space sealing step, the position (3) of the cutting step, the position (4) of the transfer step, and the position of the slow cooling step ( 5) The mold insert 3 is circulated to the position (6) of the separation process and the position (7) of the standby process.

Next, operation | movement is demonstrated in order of the position (1) of the resin conveyance process of FIG. 1-the position (7) of a standby process.
At the position (1) of the resin transport process, the resin 1 is transported from the nozzle of the extruder to the shape transfer device. Since two apparatuses (extruder 20 and fine pattern processing apparatus 21) are connected to each other, the resin temperature is hardly lowered and it is economical. Polycarbonate is used as the molten resin 1 and is about 270 ° C. immediately after the conveyance, and about 200 ° C. just before the fine pattern processing apparatus 21. As shown in FIG. 2, the glass transition point GP of the polycarbonate used as the molten resin 1 is about 140 ° C., and the heat distortion temperature (deflection temperature under load) HDT is about 120 ° C.

  In the position (2) of the transfer space sealing step to the position (5) of the slow cooling step, the temperature of the conveyed molten resin 1 is a temperature at which the plastic processing can be sufficiently performed at the glass transition temperature or higher. The temperature of the mold insert 3 at that time is equal to or higher than the heat deformation temperature (deflection temperature under load). Next, the support body 4 is advanced from the mold insert 3 and is in contact with the resin 1 to form the space S. When this space S is open, carbon dioxide G is supplied, and after the carbon dioxide G is sealed between the spaces S, the support 4 is advanced to the molten resin 1 and the molten resin 1 is cut. Next, the mold is gradually advanced until the fine pattern 2 on the surface of the mold insert 3 comes into contact with the resin. The carbon dioxide G sealed between the mold insert 3 and the resin 1 is pressurized by the advance of the mold insert 3 and impregnates the resin surface layer. The fine shape pattern 2 is pressed and transferred to the resin surface layer impregnated with carbon dioxide G and the melt viscosity is lowered. The temperature of the mold insert 3 is gradually lowered, and the molten resin 1 is cooled to the heat deformation temperature (deflection temperature under load) or less before reaching the position (5) of the slow cooling step. For example, the temperature of the molten resin 1 immediately before pressurization is 200 ° C., and the temperature of the molten resin 1 immediately before the mold insert 3 is detached is 130 ° C.

  At that time, the resin supply speed and the moving speed of the mold insert 3 from the position (2) in the transfer space sealing step to the position (5) in the slow cooling step are the same. As a result, the amount of resin during molding becomes constant, and stable pressurization of carbon dioxide and pressurization of the mold insert 3 to the resin are possible. For example, if the moving speed of the mold insert 3 is slower than the resin supply speed, the resin will be jammed when the resin is cut by the mold insert 3 and the jammed portion will be cut at the next cutting. The amount of resin during molding is not constant. Further, if the moving speed of the mold insert 3 is faster than the resin supply speed, a space is generated between the resin and the cut portion when the resin is cut by the mold insert 3, and a space portion is formed at the next cutting. The amount of resin at the time of molding is not constant.

  At the position (6) in the separation step, the mold insert 3 is detached from the molded product 1b. At that time, since the resin temperature is equal to or lower than the thermal deformation temperature (deflection temperature under load), the fine shape pattern 2 is not deformed, and a high-quality molded product is obtained. At the position (7) in the standby process, the mold insert 3 released from the molded product 1b moves to the position (2) in the transfer space sealing process and performs the next transfer process. During the movement, the temperature of the mold insert 3 is heated to a predetermined temperature.

  Further, when pressurization is performed by the mold insert 3 set to be equal to or lower than the heat distortion temperature (deflection temperature under load), the cooling of the molten resin 1 is promoted and the molding cycle is shortened. The surface to be transferred is also cooled and solidified, but the transfer accuracy of the fine pattern 2 is not lowered by the plasticizing effect of the carbon dioxide G sealed in the space S. Further, since the resin shrinks due to cooling and solidification, a gap is formed between the mold insert 3 and the carbon dioxide G sealed in the space S is discharged to the outside and the carbon dioxide G does not intervene on the transfer surface. The transfer accuracy of the pattern 2 is increased. In this case, the inside of the fine pattern processing apparatus 21 is not made the atmosphere of carbon dioxide G, but a carbon dioxide G supply hole is provided in the mold insert 3 as shown in FIG. G is supplied.

  Next, a transfer processing method to a molded product using the transfer processing apparatus of FIG. 1 will be described. FIG. 3 shows a first example of a fine pattern transfer method using the transfer processing apparatus of FIG. 1, wherein (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. . In this transfer processing method, the transfer processing apparatus of FIG. 1 is used, but the case where the cutting step is omitted and the transfer space sealing step, the transfer step, and the separation step are performed will be described.

  As shown in FIG. 3, this transfer processing method shows a method for transferring a fine pattern using a mold insert 3 in which protrusions 5 are provided around the fine pattern 2. In FIG. 3 (A), a space formed by the molten resin 1 extruded from the nozzle 20a (plasticizing cylinder) and a mold insert 3 having a fine pattern 2 on its surface and provided with a protrusion 5 around it. S is in a sealed state when the molten resin 1 and the protrusion 5 are in contact with each other. The space S is filled with a gas body capable of obtaining a plasticizing effect when impregnated with resin, in the present embodiment, carbon dioxide G.

  In addition to carbon dioxide, gas bodies that are easily dissolved in thermoplastic resins and easily obtain a plasticizing effect include hydrocarbons, gases in which part of the hydrocarbons are substituted with fluorine, etc., but they are easily dissolved in thermoplastic resins. It is particularly good to use carbon dioxide, which is easy to handle.

  In FIG. 3B, the mold insert 3 is pressurized and advanced to compress the carbon dioxide G to a high pressure state. The pressure of the sealed carbon dioxide G can be adjusted to an arbitrary pressure by the pressing force of the mold insert 3, but when the pressure of the carbon dioxide G is 73 MPa or higher, the temperature of the molten resin 1 is 30 ° C. or higher. Therefore, the carbon dioxide G becomes a supercritical state, and the impregnation of the resin surface layer is further accelerated. Since the carbon dioxide G impregnated in the resin surface layer acts as a plasticizer, an effect of selectively lowering the solidification temperature of only the resin surface layer or lowering the melt viscosity of the resin is obtained. In this state, the fine insert pattern 3 on the surface of the mold insert 3 can be accurately transferred to the resin by tightly pressing the mold insert 3 on the surface of the molten resin. In FIG. 3C, after the fine pattern 2 is transferred and the resin is cooled and solidified, the mold insert is moved backward. In this way, the fine pattern is transferred to the resin surface layer with high accuracy.

  Next, the operation of increasing / decreasing carbon dioxide will be described in the order of FIGS. 4A and 4B are diagrams for explaining the operation of increasing / decreasing carbon dioxide using a mold insert provided with a pressure reducing valve. FIG. 4A is before transfer, FIG. 4B is during transfer, and FIG. 4C is after transfer. Respectively. In this transfer processing method as well, as in the transfer processing method shown in FIG. 3, a case where the cutting step is omitted will be described.

  In FIG. 4A, the space S formed by the molten resin 1 extruded from the nozzle 20a and the mold insert 3 having the fine pattern 2 on the surface is sealed by the molten resin 1 and the mold insert 3 being in contact with each other. It becomes a state. The space S is filled with carbon dioxide G.

  In FIG. 4B, the mold insert 3 is pressurized and advanced to compress the carbon dioxide G to a high pressure state. The pressure of the sealed carbon dioxide G can be adjusted to an arbitrary pressure by the pressing force of the mold insert 3. By setting the pressure release valve 9 to open at an arbitrary pressure or higher, or by setting the pressure release valve 9 to open when the fine pattern 2 comes to the stroke position in contact with the resin, the fine pattern 2 When transferring to the resin, carbon dioxide does not intervene between the resin and the mold insert 3 to prevent the transfer of the fine pattern 2.

  Until the pressure release valve 9 is opened, the carbon dioxide G is pressurized and impregnated into the resin surface layer, so that an effect of selectively lowering the solidification temperature of only the resin surface layer or lowering the melt viscosity of the resin is obtained.

  In FIG. 4C, after the fine pattern is transferred and the resin is cooled and solidified, the mold insert 3 is moved backward. The fine pattern 2 is transferred to the resin surface layer with high accuracy. At this time, by blowing clean air between the resin 1 and the fine pattern 2 on the surface of the mold insert 3, it is possible to accelerate the release of the molten resin 1 and the mold insert 3 with high accuracy.

  FIG. 5 is a diagram showing an example of a circuit diagram for supplying carbon dioxide heated outside to the space S. FIG. In FIG. 5, not the pressurization of the carbon dioxide G by the forward pressurization of the mold insert 3 and the heating using the temperature of the molten resin 1 but the carbon dioxide G heated outside is supplied to the space S. An example of a circuit diagram for doing this is shown.

  By supplying carbon dioxide G heated externally, carbon dioxide G can be impregnated into the solid resin 1a supplied in a solid state such as a sheet. Further, as shown in FIG. 5, it is only necessary to add a simple heating device 10 such as a heater in the middle of supplying the gas to the space S, and it does not become large like a pressurizing device. In the present embodiment, the heating device 10 is disposed between the gas supply source 13 and the gas reservoir 11. In FIG. 8, reference numeral 12 denotes a valve.

  FIG. 6 shows a second example of a fine pattern transfer method using the transfer processing apparatus of FIG. 1, wherein (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. . Also in this case, the cutting step is omitted as in the transfer processing method described with reference to FIG.

  In FIG. 6A, the space S formed by the molten resin 1 extruded from the plasticizing cylinder, the mold insert 3 having the fine pattern 2 on the surface, and the support 4 of the mold insert 3 is melted. The resin 1 and the support 4 are brought into contact with each other to be in a sealed state. The space S is filled with a gas body that provides a plasticizing effect when impregnated with resin. As the gas body that is easily dissolved in the thermoplastic resin and easily obtains a plasticizing effect, it is particularly preferable to use carbon dioxide that is easily dissolved in the thermoplastic resin and easy to handle, as in the transfer processing method of FIG.

  In FIG. 6B, the mold insert 3 is pressurized and advanced to compress the carbon dioxide G to a high pressure state. The pressure of the sealed carbon dioxide G can be adjusted to an arbitrary pressure by the pressing force of the mold insert 3, but when the pressure of the carbon dioxide G is 73 MPa or higher, the temperature of the molten resin 1 is 30 ° C. or higher. Therefore, the carbon dioxide G becomes a supercritical state, and the impregnation of the resin surface layer is further accelerated. Since the carbon dioxide G impregnated in the resin surface layer acts as a plasticizer, an effect of selectively lowering the solidification temperature of only the resin surface layer or lowering the melt viscosity of the resin is obtained. In this state, the fine insert pattern 3 on the surface of the mold insert 3 can be accurately transferred to the resin by tightly pressing the mold insert 3 on the surface of the molten resin. In FIG. 6C, after the fine pattern 2 is transferred and the resin is cooled and solidified, the mold insert is retracted. The fine pattern 2 is transferred to the resin surface layer with high accuracy.

  As described above, according to the transfer processing method or transfer processing apparatus of the embodiment of the present invention, the molten resin 1 supplied from the extruder 20 and the mold insert 3 having the fine pattern 2 on the surface are melted. When the resin 1 is impregnated, the carbon dioxide G, which is a gas body that can obtain a plasticizing effect, is sealed, and the carbon dioxide G is compressed to a high pressure by advancing the mold insert 3, whereby the carbon dioxide G is applied to the resin surface layer. Impregnation to reduce the viscosity of the resin surface layer. Thereafter, the resin surface layer is pressed with a mold insert 3 having the fine shape pattern 2 on the surface, and the fine shape pattern 2 is transferred to the resin surface layer, thereby obtaining a molded product 1b on which the fine shape pattern 2 is transferred with high accuracy. be able to.

  FIG. 7 is a diagram for explaining the operation of the transfer processing apparatus according to the second embodiment of the present invention. Next, as another embodiment, the operation will be described in the order of the position (1) of the resin transport process to the position (7) of the standby process in FIG.

  At the position (1) of the resin transport process, the molten resin 1 is transported from the extruder 20 to the fine pattern processing device 21. Since the two devices are connected, there is little decrease in the resin temperature and it is economical. For example, the molten resin 1 is polycarbonate, about 270 ° C. immediately after conveyance, and about 200 ° C. just before the fine pattern processing apparatus 21.

  In the position (2) of the transfer space sealing step to the position (5) of the slow cooling step, the temperature of the conveyed molten resin 1 is a temperature at which the plastic processing can be sufficiently performed at the glass transition temperature or higher. The temperature of the mold insert 3 at that time is equal to or higher than the heat deformation temperature (deflection temperature under load). Next, after supplying carbon dioxide G between the molten resin 1 and the mold insert 3 and sealing the carbon dioxide G between the spaces S, the fine shape pattern 2 on the surface of the mold insert 3 is formed on the molten resin 1. Slowly advance until it comes in contact with the resin. At the same time, the projection 5 on the side of the mold insert 3 penetrates the resin and cuts out the outer shape of the molded product. The carbon dioxide G sealed between the mold insert 3 and the molten resin 1 is pressurized by the advancement of the mold insert 3 and impregnates the resin surface layer. The fine shape pattern 2 is pressed and transferred to the resin surface layer impregnated with carbon dioxide G and the melt viscosity is lowered. A mold (moving symmetrically with the mold insert 3 with respect to the molten resin 1) 7 having a concave groove 8 (see FIG. 8) that is aligned with the protrusion 5 on the opposite side of the mold insert 3 with the molten resin 1 interposed therebetween Since the molded product 1b cut out is pressed and pressed, the carbon dioxide G sealed in the space S and the fine pattern 2 can be pressed to the molten resin 1 with higher pressure, and the transfer accuracy Is obtained. The temperature of the mold insert 3 is gradually lowered, and the resin is cooled to the heat deformation temperature (deflection temperature under load) or less before reaching the position (5) of the slow cooling step. For example, the temperature immediately before pressurization is 200 ° C., and the temperature immediately before the mold insert 3 is detached is 130 ° C.

  At that time, the resin supply speed and the moving speed of the mold insert 3 from the position (2) in the transfer space sealing step to the position (5) in the slow cooling step are the same. As a result, the amount of resin during molding becomes constant, and stable pressurization of carbon dioxide G and pressurization of the mold insert 3 into the resin are possible.

  At the position (6) in the separation step, the mold insert 3 is detached from the molded product 1b. At that time, since the resin temperature is equal to or lower than the thermal deformation temperature (deflection temperature under load), the fine shape pattern 2 is not deformed, and a high-quality molded product is obtained. At the position (7) in the standby process, the mold insert 3 released from the molded product 1b moves to the position (2) in the transfer space sealing process and performs the next transfer process. During the movement, the temperature of the mold insert 3 is heated to a predetermined temperature.

  FIG. 8 shows a first example of a fine pattern transfer method using the transfer processing apparatus of FIG. 5, where (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. . FIG. 8 shows a fine shape pattern transfer method using a mold insert 3 having a protrusion 5 higher than the surface of the fine pattern 2 around the fine pattern 2 and a mold 7 having a groove 8 at a position corresponding to the protrusion 5.

  In FIG. 8 (A), the space S formed by the mold insert 3 having the molten resin 1 extruded from the plasticizing cylinder and the finely shaped pattern 2 on the surface and provided with protrusions 5 around the molten resin 1 is the molten resin 1. And the projection 5 come into contact with each other to form a sealed state. The space S is filled with a gas body that provides a plasticizing effect when impregnated with resin. As the gas body that is easily dissolved in the thermoplastic resin and easily obtains the plasticizing effect, it is particularly preferable to use carbon dioxide as in the transfer processing method of FIG.

  In FIG. 8 (B), the mold insert 3 is advanced to shear the molten resin 1 by the protrusions 5, and the carbon dioxide sealed between the sheared molten resin 1 and the mold insert 3 is compressed and pressurized. It becomes a state. The pressure of the sealed carbon dioxide can be adjusted to an arbitrary pressure by the pressurizing force of the mold insert 3, but when the pressure of the carbon dioxide is 73 MPa or higher, the temperature of the molten resin 1 is 30 ° C. or higher. Carbon dioxide becomes a supercritical state, and the impregnation of the resin surface layer is further accelerated. Since carbon dioxide impregnated in the resin surface layer acts as a plasticizer, an effect of selectively lowering the solidification temperature of only the resin surface layer or lowering the melt viscosity of the resin is obtained. In this state, the mold insert 3 is advanced and the protrusion 5 penetrating through the molten resin 1 is aligned with the concave groove 8 at a position corresponding to the protrusion 5 to cut the molten resin 1 and finely form the surface of the molten resin. The finely shaped pattern 2 can be accurately transferred to the resin by tightly pressing the pattern 2.

  In FIG. 8C, after the fine pattern 2 is transferred and the resin is cooled and solidified, the mold insert 3 is moved backward. A fine shape pattern is transferred with high accuracy on the resin surface layer, and a predetermined molded product shape is also formed by the protrusions 5.

  FIG. 9 shows a first example of a fine pattern transfer method using the transfer processing apparatus of FIG. 7, where (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. . FIG. 9 shows a method of fine shape pattern transfer using a nest 6 and a mold 7 having a concave shape that fits into the nest 6 and having a fine pattern 2 on the bottom surface of the concave shape. In FIG. 9A, the molten resin 1 pushed out from the nozzle 20a is moved forward by moving the mold 7 having the fine pattern 2 on the bottom surface of the concave shape, so that the molten resin 1 and the mold 7 are brought into contact with each other to form the space S formed. Is hermetically sealed.

  The space S is filled with carbon dioxide as a gas body that provides a plasticizing effect when impregnated with resin, as in the transfer processing method of FIG. In FIG. 9B, the molten resin 1 is sheared by advancing the nest 6 under pressure, and the carbon dioxide G sealed between the sheared molten resin 1 and the mold 7 is compressed into a high pressure state. The pressure of the sealed carbon dioxide G can be adjusted to an arbitrary pressure by the pressurizing force of the nesting 6, but when the pressure of the carbon dioxide G is 73 MPa or higher, the temperature of the molten resin is 30 ° C. or higher. Carbon dioxide G enters a supercritical state, and the impregnation of the resin surface layer is further accelerated. Since the carbon dioxide G impregnated in the resin surface layer acts as a plasticizer, an effect of selectively lowering the solidification temperature of only the resin surface layer or lowering the melt viscosity of the resin is obtained. In this state, the insert 6 is moved forward so that the molten resin surface layer is brought into close contact with the fine pattern 2 on the concave bottom surface of the mold 7 so that the fine pattern 2 can be accurately transferred to the resin. In FIG. 9C, after the fine shape pattern 2 is transferred and the resin is cooled and solidified, the insert 6 is moved backward. On the resin surface layer, the fine pattern 2 is transferred with high accuracy, and a predetermined molded product shape is also formed by the concave shape of the mold 7.

  10A and 10B are diagrams showing a first specific example of the temperature adjusting means provided in the nesting, in which FIG. 10A is a schematic configuration diagram, and FIG. As shown in FIG. 10A, the mold insert 3 is formed with a flow path 3 b for passing a cooling medium from the heat exchanger 15 through the flexible tube 14.

  The flexible tube 14 is made of a heat-resistant resin having flexibility such as nylon, polyamide, and polyolefin, and can follow the moving mold insert 3. As the cooling medium of the heat exchanger 15, a water cooling type using water is preferable. The reason is that it is excellent in handling and has high heat exchange efficiency. The cooling medium may be always circulated in the mold insert 3 so that the mold insert 3 is always kept at a constant temperature. Further, the cooling medium in the mold insert 3 may be extracted until the pressurization is completed, or the circulation may be stopped, and after the pressurization is completed, the cooling medium may be circulated in the mold insert 3 to be cooled. . Furthermore, the temperature of the cooling medium may be gradually lowered from the thermal deformation temperature (the deflection temperature under load) of the resin to a predetermined temperature or room temperature, and gradually cooled.

  FIG. 11 is a view showing a second specific example of the temperature adjusting means provided in the mold insert. As shown in FIG. 11, a baffle plate 18 and / or a pipe (not shown) is arranged in a hole 3a drilled perpendicularly to the fine pattern 2 in the mold insert 3 to circulate the cooling medium. You may make it do.

  12A and 12B are diagrams showing the flow path of the temperature adjusting medium facing the transfer pattern surface, where FIG. 12A shows the flow paths arranged in parallel, and FIG. 12B shows the flow paths arranged in a spiral. . As shown in FIG. 12A, in order to reduce the temperature variation on the surface of the fine shape pattern 2, the flow path of the cooling medium may be bent by reciprocating partly in parallel. Further, as shown in FIG. 12B, the cooling medium may be bent so as to reciprocate in a spiral manner. In these examples, an example in which one flow path is bent is shown, but a plurality of flow paths may be formed in one mold insert 3.

  FIG. 13 is a diagram showing a third specific example of the temperature adjusting means provided for the nesting. As shown in FIG. 13, in addition to the method of circulating the cooling medium described above, there is also a method of cooling by inserting the heat pipe 16 into the mounting hole of the heat pipe 16 provided in the mold insert 3. In this method, in addition to continuing to insert the heat pipe 16 into the mold insert 3, the heat pipe 16 is removed until the pressurization is completed, and in this state, the temperature is kept at a temperature higher than the heat deformation temperature (). The heat pipe 16 may be inserted into the mounting hole for cooling. By using the heat pipe 16 in this way, a tube or the like for circulating the cooling medium becomes unnecessary, and the structure becomes simple. Thereby, maintenance becomes easy and cost reduction can also be measured. The present invention is not limited to the above embodiment. For example, in the above-described embodiments of FIGS. 1 and 5, the case where there are five mold nestings has been described. However, the number may be one or more and less than five, or may be six or more. That is, various modifications can be made without departing from the scope of the present invention.

It is operation | movement explanatory drawing of the transfer processing apparatus of 1st Embodiment which concerns on this invention. It is a figure which shows the temperature of the resin in each process of FIG. 1A and 1B show a first example of a fine shape pattern transfer processing method using the transfer processing apparatus of FIG. 1, (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. It is a figure for demonstrating the operation | movement of the pressure increase / decrease of a carbon dioxide using the nest | insert provided with the pressure-reduction valve, (A) shows before transfer, (B) is during transfer, (C) shows after transfer. It is a figure which shows an example of the circuit diagram for supplying the carbon dioxide heated outside to the space S. FIG. 2A and 2B show a second example of a fine shape pattern transfer processing method using the transfer processing apparatus of FIG. 1, (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. It is operation | movement explanatory drawing of the transfer processing apparatus of 2nd Embodiment which concerns on this invention. 7 shows a first example of a fine shape pattern transfer processing method using the transfer processing apparatus of FIG. 7, wherein (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. 7 shows a first example of a fine shape pattern transfer processing method using the transfer processing apparatus of FIG. 7, wherein (A) shows before transfer, (B) shows during transfer, and (C) shows after transfer. It is a figure which shows the 1st specific example of the temperature adjustment means with which a nesting is equipped, (A) is a schematic block diagram, (B) is the sectional view on the AA line in (A) figure. It is a figure which shows the 2nd specific example of the temperature control means with which a nesting is equipped. It is a figure which shows the flow path of the medium for temperature adjustment facing a transfer pattern surface, (A) shows the flow path arrange | positioned in parallel, (B) shows the flow path arrange | positioned spirally. It is a figure which shows the 3rd specific example of the temperature control means with which a nesting is equipped.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molten resin 1a Solid resin 1b Molded product 2 Fine shape pattern 3 Mold insert (transfer body)
3a hole 3b flow path 4 support 5 protrusion 6 nesting 7 type (transfer body)
8 Groove 9 Pressure release valve 10 Heating device 11 Gas reservoir 12 Valve 13 Gas supply source 14 Flexible tube 15 Heat exchanger 16 Heat pipe 17 Heat sink 18 Baffle plate 20 Extruder 20a Nozzle 21 Fine pattern processing device 22 Conveying means C Cutter G Carbon dioxide (gas body with plasticizing effect)
GP Glass transition point HDT Thermal deformation temperature (deflection temperature under load)

Claims (14)

  After impregnating the surface layer of the melted resin with a gas body having a plasticizing effect, the surface of the resin impregnated with the gas body is pressurized with the fine pattern of the transfer body having a fine pattern on the surface, and the gas A fine shape transfer processing method, wherein the fine pattern is transferred onto the surface of a resin impregnated with a body.   A resin body impregnated with a gas body by impregnating the surface layer of the molten resin with a gas body having a plasticizing effect and then pressing a nest having a fine pattern on the surface of the resin impregnated with the gas body A fine pattern transfer processing method, wherein a fine pattern is transferred to the surface of the substrate.   The impregnation of the gas body is performed by sealing the gas body having a plasticizing effect by the surface of the molten resin and the nesting having a fine pattern on the surface, and by moving the nesting forward toward the resin surface. 3. The fine shape transfer processing method according to claim 2, wherein the gas body is pressurized to impregnate the surface layer of the resin with the gas body.   3. The fine shape transfer processing method according to claim 2, wherein the nesting has a protrusion that surrounds the periphery of the fine pattern and protrudes from a fine pattern surface.   3. The fine shape transfer processing method according to claim 2, wherein the molten resin is cut and processed into a predetermined molded product shape together with an operation of transferring the fine pattern by pressing the insert. .   A gas having a plasticizing effect of the resin in the concave portion of the mold, the molten resin being sandwiched between the mold and a mold having a recess that is fitted with the insert and a bottom surface of the recess. After filling the body, the mold is advanced toward the resin, the resin is cut, and then the fine pattern is pressed onto the resin to transfer the fine pattern onto the surface of the resin. Fine shape transfer processing method.   Gas having a plasticizing effect of the resin in the recessed portion of the insert, having a mold and a recessed portion fitted with the mold, and sandwiching a molten resin between the bottom of the recessed portion and having a fine pattern After filling the body, the insert is advanced toward the resin, the resin is cut, the fine pattern is pressed against the resin, and the fine pattern is transferred to the surface of the resin. Fine shape transfer processing method.   A fine shape transfer processing method, wherein a plurality of fine patterns are transferred by repeatedly performing the fine shape transfer processing method according to claim 2 on one molten resin surface.   An extruder for supplying a molten resin and a fine pattern processing apparatus for pressurizing and transferring a fine pattern by impregnating a gas body having a plasticizing effect are connected to each other, and the transfer body is connected at the same speed in conjunction with a resin supply speed. 9. The fine shape transfer processing method according to claim 8, wherein the fine pattern transfer processing is performed when the resin supply speed and the transfer body movement speed are the same.   Claims characterized in that a molten resin having a glass transition temperature or higher is pressed with a fine pattern with a nesting having a temperature adjusting function not higher than a thermal deformation temperature, and the nesting and the resin are cooled in this state, and the resin and the nesting are separated. Item 10. The fine shape transfer processing method according to Item 8 or 9.   By sealing the melted resin surface and a gas body having a plastic pattern with a nest having a fine pattern on the surface, the nest is advanced to pressurize the gas body, and the resin surface layer is impregnated with the gas body. After the melt viscosity is reduced, the pressure of the gas body is released by a pressure reducing valve, and then the fine pattern is transferred to the surface of the molten resin.   A gas body having a plasticizing effect heated to a temperature higher than the glass transition point of the resin by a heating device is supplied to the resin surface and the space formed by the nest having a fine pattern on the surface, and the gas body is added by advancing the nest. A fine shape transfer processing method, wherein the resin surface layer is impregnated with a gas body to reduce the melt viscosity of the resin surface layer, and then the fine pattern is transferred to the surface of the resin impregnated with the gas body.   Means for impregnating a melted resin surface layer with a gas body having a plasticizing effect, and means for pressing the fine pattern of the transfer body having a fine pattern on the surface of the resin impregnated with the gas body. A transfer device with a fine shape, characterized in that   14. The fine shape transfer processing apparatus according to claim 13, wherein the molten resin is supplied at the same speed as the transfer body.

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