JP2007050517A - Reversal mold, manufacturing method of molded product, molded product and image forming device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simply manufacture a molded product reduced in the positional shift of both sides and having a fine shape such as a lens or the like formed to both sides thereof. <P>SOLUTION: The molded product is manufactured using a reversal mold 10 obtained by joining the first mold 1, which corresponds to the shape of a first surface for manufacturing the molded product by transferring the fine shape to both sides of the molded product to be manufactured, and the second mold 2 corresponding to the shape of the second surface on the back side of the first surface by an end part 3 and characterized in that the joining part of the first and second molds is constituted of at least an elastomer. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a reversal type for producing a molded product by transferring a fine shape on the order of μm on both sides, a method for producing a molded product using the reversal mold, and an image forming apparatus using the molded product.

As a method for molding a conventional molded product, for example, a lens array in which lens shapes are formed on both sides, in Patent Document 1, the resin is passed through a transparent film in which a radiation curable resin is applied and formed on both sides between a pair of molding rolls. When forming a stamper, combine the stamper on the surface of the molding roll with the stamper with periodic irregularities arranged in the axial direction of the roll surface and the stamper with periodic irregularities arranged in the outer peripheral direction of the roll surface. ing.
However, according to this method, it is possible to produce a large-area lens sheet, but position errors between the front surface and the back surface are likely to occur.
In addition to the above, there is also a forming method for attaching a lens sheet. That is, it is a method of forming a double-sided lens by heating two thermoplastic sheets and pressing them with a stamper so that two lens sheets formed with a lens surface are laminated. However, this is inferior in productivity.
In addition, there is a method using a vertical press. A front mold and a back mold are prepared separately on the upper and lower fixed plates of the press device, and each mold is assembled and placed, and a thermoplastic resin is pressed with those molds to mold both sides of the resin. To do. However, in this method, the front surface mold and the back surface mold are separately manufactured, and the respective molds are assembled and arranged to move up and down, so that a positional error between the front surface and the back surface of the resin is likely to occur.
Further, there is a method of performing three-dimensional molding with a photocurable resin with a photomask using a mask aligner. However, although this method also uses a mask aligner, alignment is possible. However, alignment is required for each molding shot, and alignment takes time and is inferior in productivity.
JP-A-8-278404

As described above, the conventional method of manufacturing a molded product has a problem that a positional error of a fine shape such as a lens formed on both the front surface and the back surface is likely to occur, and the productivity is inferior.
The present invention has been made in consideration of the above-described circumstances, and a reversible mold in which the fine shape of a lens or the like is not misaligned on both surfaces and can be easily formed, and a molded article manufactured by the reversal mold. It is an object of the present invention to provide a method and an image forming apparatus using the molded product.

In order to achieve the above object, the invention according to claim 1 is a first mold corresponding to the shape of the first surface for producing a molded product by transferring the fine shape to both surfaces of the molded product to be produced. And a second mold corresponding to the shape of the second surface on the back side of the first surface at the end, the first and second molds being molded articles to be manufactured A full-size double-sided shape transfer mold is transferred and produced, and the joining portion of the first and second molds is made of an elastic body.
According to a second aspect of the present invention, in the inversion mold according to the first aspect, at least one of the first and second molds is formed of an elastic body.
According to a third aspect of the present invention, in the inversion type according to the first or second aspect, at least one of the first or second type is made of an ultraviolet transmitting material.
According to a fourth aspect of the present invention, in the inversion mold according to the first or second aspect, at least one of the first or second mold is made of a heat-permeable material.
The invention according to claim 5 is the inversion mold according to any one of claims 1 to 4, wherein the first mold, the second mold, or the joining portion is at least partially made of silicone rubber. And
The invention of claim 6 is characterized in that, in the inversion mold according to any one of claims 1 to 4, the first and second molds or the joining portion is made of fluorinated rubber at least partially. To do.
The invention according to claim 7 is a method for manufacturing a molded product by transferring a fine shape to manufacture a molded product, wherein the first surface of the substrate and the second surface of the back surface of the first surface are manufactured. The double-sided shape transfer mold in which a fine shape corresponding to the first surface and the second surface of the molded product is formed, and the double-sided shape transfer mold is used as described in any one of claims 1 to 6. And a molded product is manufactured by transferring a fine shape onto a material using the inversion mold.
The invention according to claim 8 is the method for producing a molded article according to claim 7, wherein the substrate is made of a glass material.

The invention according to claim 9 is the method for producing a molded article according to claim 7 or 8, wherein the double-sided shape transfer mold is prepared by dry etching a glass material.
The invention of claim 10 is the method of manufacturing a molded article according to claim 7 or 8, wherein the double-sided shape transfer mold is configured to electrically measure the fine shapes of the first surface and the second surface of the substrate. It is formed by casting.
The invention of claim 11 is the method for producing a molded product according to claim 10, wherein the fine shape of the double-sided shape transfer mold is a photoresist on the first surface and the second surface of the substrate. After patterning, a metal film is formed, and after lift-off, it is formed by electroforming.
The invention of claim 12 is the method for producing a molded product according to any one of claims 7 to 11, wherein the reversal mold is a part of the double-sided shape transfer mold in a liquid before curing of an elastic body. It was produced by dipping the two-sided shape transfer mold after the pre-curing liquid was cured by leaving the film and then curing the liquid before curing.
The invention of claim 13 is the method for producing a molded product according to any one of claims 7 to 12, wherein the material of the molded product is made of an ultraviolet curable resin.
The invention of claim 14 is the method for producing a molded product according to any one of claims 7 to 12, wherein a material of the molded product is made of a thermosetting resin.
The invention of claim 15 is characterized by being manufactured using the inversion mold according to any one of claims 1 to 6.
The invention according to claim 16 is characterized by being manufactured using the manufacturing method according to any one of claims 7 to 14.
The invention of claim 17 is an image forming apparatus for forming a recorded image on a recording medium, wherein the molded product of claim 15 or 16 is used as an optical component.
The invention according to claim 18 is the image forming apparatus according to claim 17, wherein the optical component is a lens array.

  According to the present invention, it is possible to easily manufacture a molded product in which a fine shape such as a lens is formed on both surfaces, with a small positional deviation on both surfaces, and an inexpensive optical component, an optical device, and the like having stable performance. Can be provided.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a cross-sectional perspective view of an inversion type according to an embodiment of the present invention, and a diagram showing an example of a molded product manufactured with the inversion type. In FIG. 1A, the inversion mold 10 includes a first mold 1 that transfers a fine shape, and a second mold 2 that transfers the fine shape with the first mold 1 facing the transfer surface. It is made by joining at one end 3. Each of the molds 1 and 2 has molding recesses 1a and 2a. Then, by making the first mold 1 or the second mold 2 (or both) with an elastic body, the mold can be deformed and the distance between the opposing surfaces of both molds can be increased. . FIG. 1 shows a state in which the first mold 1 is deformed and the distance between the molds is increased in the direction indicated by the arrow (A), but the second mold 2 may also be an elastic body or another material. It may be made of. Furthermore, although not shown in the drawing, only the joint portion of the end 3 may be formed of an elastic body.
FIG. 1A shows a cross section of a portion where the transfer shape of the reversal mold 10 exists. Actually, the reversal mold 10 has a flat plate-shaped molded product 20 as shown in FIG. Therefore, the outer peripheral portions of the first mold 1 and the second mold 2 are flat, and a gap corresponding to the thickness of the flat molded product 20 is formed.
About the material of the 1st type | mold 1 and the 2nd type | mold 2, either (or both) is comprised with the elastic silicone rubber and the fluorinated rubber, and the shaping | molding of the plastic of a shape as shown in FIG.1 (b) The product 20 can be easily released from the mold.
Silicone rubber and fluorinated rubber can withstand temperatures of 200 ° C. or higher and transmit ultraviolet rays, so that a plastic molded product using a thermosetting resin or an ultraviolet curable resin can be produced.

FIG. 2 is a view for explaining a manufacturing process of a molded product according to the embodiment of the present invention. In the drawing, in the manufacturing step (a) of the double-sided shape transfer mold 5, a transfer shape is prepared in which fine shapes 50a precisely formed on both surfaces of the substrate 50 are combined using a double-sided aligner not shown. This double-sided shape transfer mold 5 has the same shape as the shape shown in FIG. 1B, that is, the molded product to be manufactured from now on. A method for producing the double-sided shape transfer mold 5 will be described later.
Next, the inversion mold 10 is produced (b). This step is a step of producing the reversal die 10 using the double-sided shape transfer die 5 produced in the previous step (a). The completed inverted mold 10 has a shape as shown in (c). This has been described with reference to FIG. 1, and the end portions are connected as shown in FIG.
The next step is a resin filling and curing step (e), in which the reversal mold 10 is filled with resin, the reversal mold 10 is deformed in the direction of the arrow (B) shown in the figure, and heat or ultraviolet rays are applied to apply the resin O. Harden. Then, in the mold release step (f), the resin O cured in the reversal mold 10 is demolded by deforming the mold made of the elastic body of the reversal mold 10 to complete the plastic molded product 6.
By the above method, the plastic molded product 6 in which a fine shape such as a lens is formed on both surfaces can be easily manufactured with small positional deviation.

FIG. 3 is a diagram for explaining a manufacturing process of the double-sided shape transfer mold 5. In the figure, the double-sided shape transfer mold 5 is manufactured by first applying an adhesion enhancing agent and a photoresist in order on one side of a substrate 50 such as quartz glass to form a resist film 31 (a). Then, in the photolithography step (b), the resist is exposed to a circle and developed by UV mask exposure. This is put in an oven and a reflow process (150 ° C., 5 minutes) is performed to melt and deform the remaining resist film 31 into a hemispherical shape. Next, the quartz glass material of the substrate 50 is etched into a lens shape by dry etching (d).
The same process is performed on the other surface of the substrate 50 (e to h), and the double-sided shape transfer mold 5 is obtained.
Both photolithography and dry etching are suitable for microfabrication. As a result, the master lens is formed by dry etching by aligning fine lens shapes on both sides of a substrate 50 made of quartz glass as a glass material by an aligner. It becomes.
FIG. 4 is a diagram for explaining a manufacturing process of the double-sided shape transfer mold 5 by another method. In this figure, the double-sided shape transfer mold 5 is manufactured by first applying an adhesion enhancing agent and a photoresist in order on one side of a substrate 50 such as quartz glass to form a resist film 31 (a). Then, in the photolithography step (b), the resist is exposed to a circle and developed by UV mask exposure. In this case, the resist film 31 corresponding to the shape to be left is removed. Next, in the film forming step (c), the nickel film 41 is formed by vapor deposition, and in the lift-off step (d), the nickel film 41 formed on the resist film 31 is removed and directly formed on the surface of the quartz glass. A filmed nickel pattern is obtained. The same process is performed on the other surface of the substrate 50 (eh). At this time, the positional deviation can be reduced by using the nickel film pattern on the lower surface which has been processed as a marker.
Finally, electroforming is performed with a nickel sulfamate solution to obtain a predetermined shape (i). This time, it was made into a thin film aiming at the lens shape.
In the above processing, since the fine shape is made of a material different from that of the substrate 50, the double-sided shape transfer mold 5 having a smooth surface is obtained.

FIG. 5 is a diagram for explaining a manufacturing method of the inversion mold 10 according to the embodiment of the present invention. In this example, a reversal mold 10 is produced in which one mold is made of nickel and the other mold is made of an elastic body.
First, the nickel film 41 is formed on one surface of the substrate 50 of the double-sided shape transfer mold 5 ((a), (b)). Next, a nickel mold is formed by electroforming (c). The mold release treatment agent is applied as it is to the other surface, and then a liquid precursor of silicone rubber, which is an elastic body, is poured and heated to be cured (d). Finally, the mold made of an elastic body is deformed in the direction of the arrow (C) shown in the figure, the double-sided shape transfer mold 5 is released (e), and the reversal mold 10 is completed (f).
FIG. 6 is a diagram illustrating a method for manufacturing the inversion mold 10 by another method. In this example, a reversal mold 10 in which both the first mold 1 and the second mold 2 are made of an elastic body is produced.
First, a release agent is applied to both surfaces of a double-sided shape transfer mold 5 serving as a master mold, and immersed in a liquid precursor of silicone rubber under reduced pressure and cured by heating (a, b). At this time, a part of the substrate 50 of the double-sided shape transfer mold 5 is not immersed as shown in the figure, and an opening is formed at the end portion to secure a peeling opening. Next, one of the molds cured in the previous step is deformed in the direction of the arrow (D) shown in the figure (e), and when the double-sided shape transfer mold 5 is removed, the reversal mold 10 is completed (d).

FIG. 7 is a diagram illustrating a method for manufacturing a molded product 6 using the reversal mold 10 according to the embodiment of the present invention. In this example, the molded product 6 is manufactured with a uniform material by the reversal die 10.
First, the reversal mold 10 is filled with a curable resin 51 such as an ultraviolet curable resin or a thermosetting resin, and cured by applying heat or ultraviolet rays (a, b). Next, the mold made of an elastic body is deformed in the direction of the arrow (E) shown in the figure and removed from the reversal mold 10 (c), and the plastic molded product 6 is completed (d). As described above, the plastic material is preferably a resin that can be cured by heat or ultraviolet rays. Especially when an optical component such as a lens is manufactured, highly transparent, for example, acrylic resin, oxetane (alicyclic epoxy is also used). Resin), acrylic silicone, unsaturated polyester resin, and the like.
FIG. 8 is a diagram for explaining a method of manufacturing the molded product 6 by another method. In this example, the reversal mold 10 is used to manufacture the fine shape on the flat plate 60 by transferring it later.
First, a flat plate 60 made of plastic or glass material is inserted into the reversal mold 10 as shown in FIG. The thickness of the flat plate 60 is substantially equal to the gap interval of the inversion mold 10. Next, the inverting resin 10 is filled with a curable resin 51 such as an ultraviolet curable resin or a thermosetting resin, cured by heat or ultraviolet rays, and integrated with the previously inserted flat plate 60 (b). Subsequently, the mold made of the elastic body of the reversal mold 10 is deformed in the direction of the arrow (F) shown in the figure and removed from the reversal mold 10 (c), thereby completing the plastic molded product 6 (d). The plastic material may be the same resin as described in FIG.
In this method, since the thickness of the flat plate 60 is substantially equal to the space between the gaps of the reversal mold 10, the thickness unevenness hardly occurs during molding.

FIG. 9 is a diagram for explaining a main configuration of an image forming apparatus including the molded product 6 according to the embodiment of the present invention. In the figure, an image forming apparatus 100 that forms a recorded image on a recording medium uses a molded article 6 of a lens array in which fine lenses are formed on both sides according to the present invention in a document image reading unit 130. .
The image forming unit 101 is configured to form a high-speed, high-quality toner recording image on a recording sheet of a recording medium (P), which is excellent in convenience and versatility in an electrophotographic image forming process.
The image forming apparatus 100 includes an image forming unit 101 that forms a multicolor image of toner on a recording medium (P), and a recording medium feeding that feeds the recording medium (P) in the direction indicated by an arrow (G). Unit 120, a document image reading unit 130 that reads an image of the document (O) with the molded product 6, and a full color including a discharge tray 140 that discharges and stores a recording medium (P) on which a multicolor image is formed. It is a copier.
The image forming apparatus 100 includes four image forming units 101: a yellow image forming unit 101 (Y), a magenta image forming unit 101 (M), a cyan image forming unit 101 (C), and a black image forming unit 101 (Bk). The unit is detachably mounted, and a toner recording image can be formed on the recording medium (P) by an electrophotographic image forming process.
In the image forming unit 101, an intermediate transfer belt 107 as a belt-shaped intermediate transfer member is stretched endlessly around a driving roller 108, a driven roller 109, a secondary transfer counter roller 112, and the like along a predetermined traveling path. And is driven to rotate in the direction indicated by the arrow (H) by the driving roller 108. The above-mentioned four image forming units are arranged on the upper side of the intermediate transfer belt 107, and the photosensitive drums 102 of the four image forming units are moved in the direction of the arrow (I) illustrated by a rotating body driving device (not illustrated). Driven by rotation.

In each image forming unit of each of the four image forming units 101, a charging unit 103 that performs charging processing on the surface of the photosensitive drum 102, and a laser beam on the surface of the photosensitive drum 102 around the photosensitive drum 102. A latent image forming unit 104 that forms an electrostatic latent image, a developing unit 106 that visualizes the formed electrostatic latent image, a photoconductor cleaning unit 113 that removes and collects toner remaining on the surface of the photoconductor drum 102, and the like. Has been placed.
In the image forming unit in which the yellow image forming unit 101 (Y) is arranged, the developing unit 106 develops an image of yellow (Y) toner and applies a charge having a polarity opposite to that of the toner to the primary transfer bias roller 110. As a result, the toner image on the photosensitive drum 102 is transferred onto the intermediate transfer belt 107.
Then, the toner images of each color are developed in order, such as a magenta image forming unit 101 (M), a cyan image forming unit 11 (C), and a black image forming unit 11 (Bk), and the toner is applied to the primary transfer bias roller 110 in the reverse direction. By applying a polar charge, the toner image on the photosensitive drum 102 is transferred onto the intermediate transfer belt 107.
At a predetermined position (lower side in the figure) of the intermediate transfer belt 107, a four-color toner recording image obtained by superimposing a plurality of images on the intermediate transfer belt 107 is secondarily transferred to a recording medium (P). A secondary transfer bias roller 111 is disposed. The recording medium (P) that has received the secondary transfer of the recording image of the plurality of color toners by the secondary transfer bias roller 111 is conveyed in the direction of the arrow (J) shown in the figure, and is melted and fixed by the fixing unit 114. Finally, the recording medium (P) is discharged and stored in the discharge tray 140 by the discharge roller pair 115.
In the present embodiment, the image of the original (O) placed on the original image reading unit 130 is read as read image information through the molded product 6, and the photosensitive member is irradiated with a laser beam emitted from the latent image forming unit 104. Although writing is performed on the drum 102, the lens array of the present invention may be used for writing by the latent image forming unit 104. That is, instead of using a polygon mirror, an LED array can be used, and the lens array of the present invention can also be used for condensing light at that time.

It is a figure which shows the example of the cross-sectional perspective view of the inversion type concerning embodiment of this invention, and the molded article manufactured with this inversion type. It is a figure explaining the manufacturing process of the molded article concerning embodiment of this invention. It is a figure explaining the manufacturing process of the type | mold for double-sided shape transfer. It is a figure explaining the manufacturing process of the mold for double-sided shape transfer by another method. It is a figure explaining the inversion-type manufacturing method concerning embodiment of this invention. It is a figure explaining the inversion type manufacturing method by another method. It is a figure explaining the manufacturing method of the molded article using the inversion type | mold concerning embodiment of this invention. It is a figure explaining the manufacturing method of the molded article by another method. It is a figure explaining the principal part structure of the image forming apparatus using the molded article concerning embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... 1st type | mold, 2 ... 2nd type | mold, 3 ... End part, 5 ... Double-sided shape transfer type | mold, 6 ... Molded article, 10 ... Inversion type | mold, 20 ... Flat plate shape, 21 ... Transfer shape, 31 ... Resist Numeral 41: Nickel film 50 ... Substrate 51 ... Curable resin 60 ... Flat plate 100 ... Image forming apparatus 101 ... Image forming unit 102 ... Photosensitive drum 104: Latent image forming means 130 ... Original image Reading part

Claims (18)

  The first mold for transferring the fine shape to the first surface of the molded product and the second mold for transferring the fine shape to the second surface on the back side of the first surface are joined in an openable / closable manner at the end. The first and second molds are produced by transferring the original double-sided shape transfer mold of the molded product, and the joint portion between the first mold and the second mold is formed. An inversion type characterized by comprising an elastic body.   2. The inversion mold according to claim 1, wherein at least one of the first mold and the second mold is formed of an elastic body.   3. The inversion type according to claim 1, wherein at least one of the first type and the second type is made of an ultraviolet transmitting material.   3. The inversion mold according to claim 1, wherein at least one of the first mold and the second mold is made of a heat-permeable material.   5. The inversion mold according to claim 1, wherein the first mold, the second mold, or the joining portion is made of silicone rubber at least in part.   5. The inversion mold according to claim 1, wherein the first mold, the second mold, or the joining portion is made of fluorinated rubber at least in part.   A method for producing a molded product to which a fine shape is transferred, wherein both sides are formed on the first surface and the second surface of the substrate with a fine shape corresponding to the first surface and the second surface of the molded product. A shape transfer mold is prepared, the reversal mold according to any one of claims 1 to 6 is manufactured using the double-sided shape transfer mold, and a fine shape is transferred to a material using the reversal mold. A method for producing a molded product, characterized by producing a molded product.   The method of manufacturing a molded product according to claim 7, wherein the substrate is made of a glass material.   The method for producing a molded product according to claim 7 or 8, wherein the double-sided shape transfer mold is produced by dry etching a glass material.   The method for producing a molded product according to claim 7 or 8, wherein the double-sided shape transfer mold forms the fine shapes of the first surface and the second surface of the substrate by electroforming.   The fine shape of the double-sided shape transfer mold is obtained by patterning a photoresist on the first surface and the second surface of the substrate, forming a metal film, performing lift-off, and performing electroforming. It forms, The manufacturing method of the molded article of Claim 10 characterized by the above-mentioned.   The reversal mold was prepared by immersing the liquid before curing, leaving a part of the mold for double-sided shape transfer, curing the liquid before curing, and then releasing the mold for double-sided shape transfer. The method for producing a molded product according to any one of claims 7 to 11, wherein   The method for manufacturing a molded product according to any one of claims 7 to 12, wherein a material of the molded product is made of an ultraviolet curable resin.   The method for manufacturing a molded product according to any one of claims 7 to 12, wherein a material of the molded product is made of a thermosetting resin.   A molded article manufactured using the reversal mold according to any one of claims 1 to 6.   A molded product produced using the production method according to claim 7.   An image forming apparatus for forming a recorded image on a recording medium, wherein the molded product according to claim 15 or 16 is used as an optical component.   The image forming apparatus according to claim 17, wherein the optical component is a lens array.

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