JP2010105270A - Apparatus and method for manufacturing resin molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus and a method for manufacturing a resin molding which enable the ready and high-precision transfer of a mold transfer surface having a fine irregular pattern to the surface of the resin molding without use of a complicated driver for driving while keeping a high pressure of carbon dioxide gas. <P>SOLUTION: A mold 2 having a transfer surface 3 and a resin molding holding portion 9 holding a resin molding 101 to be transferred with the transfer surface 3 are housed in the first closed vessel 6. A movable member 8 moving through a middle wall 5 is arranged, and a pressing portion 8b pressing the movable member 8 toward the transfer surface 3 of the mold 2 is arranged in the second closed vessel 7 in a movable way. Carbon dioxide gas is supplied into the first and second closed vessels 6 and 7. While the surface of the resin molding 101 is plasticized with the carbon dioxide gas in the first closed vessel 6, the movable member 8 is moved by adjusting the pressures of the carbon dioxide gas in the first and second closed vessels 6 and 7 so as to press the resin molding 101 toward the transfer surface 3 of the mold 2, and then the resin molding 101 is released. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a manufacturing apparatus and a manufacturing method suitable for manufacturing a resin molded product having a highly accurate transfer surface, and in particular, a resin molding suitable as an optical element having a highly accurate optical mirror surface or fine pattern on the surface. The present invention relates to a resin molded product manufacturing apparatus and a manufacturing method suitable for manufacturing a product.

  As a method for producing a resin molded product, an injection molding method is generally used. The injection molding method is a method in which a molten resin is filled in a mold cavity that is heated and maintained at a temperature equal to or lower than its softening temperature and solidified. According to this method, cooling and solidification starts immediately after the resin is filled in the cavity, and a three-dimensional shaped molded product can be produced with a very fast molding cycle. However, in this case, since the resin is cooled immediately after being filled in the cavity and a solidified layer is formed, the resin is formed particularly in a molded product having a fine uneven pattern on the surface such as a diffraction lens or a light guide plate. However, it solidifies before filling the fine concavo-convex pattern, resulting in a problem that the fine concavo-convex pattern cannot be accurately formed on the resin molded product.

  As another method for producing a resin molded product, there is a method of transferring the above-described fine pattern onto the resin surface, and a thermal imprint method is known as this transfer method. This is because the resin is heated above its softening temperature to press the transfer surface of the mold on which the fine pattern is formed, transferred to the resin surface, and then cooled to below the softening temperature to release the molded product from the transfer surface. It is a way to mold. In this case, since the resin is heated to the softening temperature or higher at the time of pressing, it becomes possible to transfer the fine pattern to the resin surface with high accuracy. However, the steps of heating and cooling the resin are necessary. There is a problem that the molding time becomes long.

  In recent years, a plurality of attempts have been made to apply carbon dioxide gas to the molding process for such problems. It is known that when an inert gas such as carbon dioxide gas is dissolved in a resin at a high pressure, the resin is plasticized and its softening temperature is lowered. Attempts have been made to form on the resin surface.

  For example, Patent Document 1 proposes a method in which a mold cavity is filled with carbon dioxide gas in advance, and then a resin is filled in the mold cavity and injection molding is performed. In this case, the carbon dioxide gas filled in the mold cavity decreases the softening temperature of the resin in the cavity, and the viscosity of the resin decreases accordingly, and the fine pattern (transfer surface) of the mold is not filled. The fine pattern can be accurately formed on the resin surface by being promoted. However, since the carbon dioxide gas is dissolved with the flow of the resin, the flow of the resin becomes unstable, and the appearance defect associated therewith occurs in the molded product. Further, since the resin is filled in the cavity pressurized with the high-pressure carbon dioxide gas, a problem such as unfilling of the molded product is likely to occur.

  On the other hand, in order to solve the above problems, in Patent Document 2, after the resin is filled in the mold cavity to form the resin molded body, the transfer surface of the mold and the skin on the surface of the resin molded body are formed. A gap is formed between the layers, carbon dioxide gas is injected into this gap to plasticize the skin layer, the holding pressure is increased again, the plasticized skin layer and the transfer surface are brought into close contact, and fine irregularities on the transfer surface It has been proposed to transfer a pattern with high accuracy. In this method, since the carbon dioxide gas can be dissolved in the skin layer without causing the resin to flow, it is possible to reduce the above-described poor appearance due to the flow. However, in this method, a gap is formed between the transfer surface of the mold and the skin layer on the surface of the resin molded body, and then a movable part is required around the transfer surface to re-adhere the transfer surface. It is difficult to maintain, and problems such as leakage of carbon dioxide gas from the movable part occur, and high pressure gas cannot be injected stably. Furthermore, when pressure is applied by holding pressure after the resin flows, the stress concentrates only in the vicinity of the gate portion which is the resin inlet, so that the pressure cannot be uniformly applied to the transfer surface.

  Further, in order to improve the problems caused by the method described in Patent Document 2, as shown in Patent Document 3, a toggle-type press drive unit for pressing the resin base material sheet against the transfer surface formed on the mold is used. Then, carbon dioxide gas is injected into the sealed mold cavity to plasticize the surface of the resin base material sheet, and then the resin base material sheet is pressed against the mold transfer surface by a press drive unit to form a fine pattern on the transfer surface. It has been proposed to transfer to the surface of the material sheet. In this case, since the plasticization is accelerated by impregnating the resin base material sheet with carbon dioxide gas, a fine pattern can be formed at a low temperature without heating the resin or mold to a high temperature as in the conventional thermal imprint method. Therefore, the molding time can be shortened. However, there is a need for a toggle-type press drive for pressing the resin matrix sheet against the transfer surface formed on the mold in a sealed mold cavity that can withstand high-pressure gas, and to maintain high pressure. The problem arises that the device is complicated and expensive because it needs to be driven with its sealing performance secured.

Japanese Patent No. 3096904 Japanese Patent No. 3445778 JP 2006-175755 A

  The present invention has been made in consideration of such conventional problems, and without using a complicated driving device for driving while maintaining the high pressure of carbon dioxide gas, the resin molded body can be obtained in a short time. It is an object of the present invention to provide a manufacturing apparatus and a manufacturing method for manufacturing a resin molded product capable of transferring a mold transfer surface having a fine concavo-convex pattern formed thereon with high accuracy.

In order to solve the above problems, the invention described in claim 1 is a mold having at least one transfer surface, a transfer surface of the mold that is disposed opposite to the transfer surface of the mold, and A resin molded body holding portion that holds a resin molded body holding the resin molded body to be transferred, and the resin molded body holding portion at one end, and the resin molded body holding portion is a transfer surface of the mold A movable member that is movably attached to the movable member, a pressing means that presses the pressing portion that is the other end opposite to the one end of the movable member toward the transfer surface of the mold, and the first sealed tank. An apparatus for producing a resin molded product having a supply port for supplying carbon dioxide gas to be impregnated into the resin molded body and a discharge port for discharging the carbon dioxide gas from a first sealed tank,
The other end of the movable member is accommodated in a second sealed tank connected to the first sealed tank via an intermediate wall,
An intermediate portion between the resin molded body holding portion and the pressing portion of the movable member is attached to the intermediate wall so as to be movable through the intermediate wall,
The pressing means is a pressing means that moves the movable member by pressing the pressing portion of the movable member by the pressure of the gas supplied into the second sealed tank.
A resin molded product is manufactured by moving the movable member and transferring the transfer surface of the mold onto the surface of the resin molded body held on the resin molded body holding portion.

The invention of claim 2 is the resin molded product manufacturing apparatus according to claim 1,
The gas supplied to the second sealed tank is carbon dioxide gas, and the carbon dioxide gas having the same pressure as the carbon dioxide gas supplied to the first sealed tank is supplied to supply the carbon dioxide gas to the resin molding. It is impregnated.

The invention of claim 3 is the resin molded product manufacturing apparatus according to claim 1 or 2,
When the gas pressure of the carbon dioxide gas supplied to the first sealed tank is P1, and the gas pressure of the gas supplied to the second sealed tank is P2, the pressure of the movable member is set by P2> P1. The movable member is moved so as to separate and peel the resin molded body from the transfer surface of the mold by pressing the part, pressing the resin molded body against the transfer surface of the mold, and setting P2 <P1. It is characterized by making it.

The invention of claim 4 is the resin-molded article manufacturing apparatus according to any one of claims 1 to 3,
When the area of the resin molded body holding surface of the resin molded body holding portion of the movable member is S1, and the area of the pressed surface of the pressing portion of the movable member is S2, the relationship between S1 and S2 is S1 < It is characterized by S2.

The invention of claim 5 is the resin molded product manufacturing apparatus according to any one of claims 1 to 4,
An elastic member is disposed between the intermediate wall and the pressing portion of the movable member, and gas is supplied into the second sealed tank so that the pressing portion of the movable member faces the transfer surface of the mold. When moved, when the elastic member is pressed and the pressure of the gas in the second sealed tank is reduced, the elastic recovery force of the elastic member causes the elastic member on the resin molded body holding portion of the movable member. The resin molded body is separated from the transfer surface of the mold.

The invention of claim 6 is the apparatus for producing a resin molded product according to any one of claims 1 to 5,
The first sealed tank and the second sealed tank are provided with first and second temperature control devices for controlling the temperature in each tank, respectively, and gas of equal pressure is supplied to the first sealed tank and the second sealed tank. In this case, the first and second temperature control devices are controlled so that T1 <T2 when the tank temperature T1 of the first sealed tank and the tank temperature T2 of the second sealed tank are set. As the gas in the second sealed tank expands, the movable member is moved and the resin molded body on the resin molded body holding portion of the movable member is pressed against the transfer surface of the mold to transfer the mold. The surface is transferred to the surface of the resin molded body.

The invention of claim 7 is the resin molded product manufacturing apparatus of any one of claims 1 to 6,
The intermediate wall is formed of a heat insulating member.

The invention according to claim 8 is characterized in that carbon dioxide gas is supplied into a first sealed tank containing a mold having at least one transfer surface and a resin molded body, and the carbon dioxide gas is supplied to the resin molded body. In the method for producing a resin molded article, after that, the resin molded body surface is pressed against the transfer surface of the mold, and the transfer surface is transferred to the surface of the resin molded body.
Using the apparatus for producing a resin molded product according to any one of claims 1 to 7,
Gas is supplied into the second sealed tank to move the movable member toward the transfer surface of the mold, and the resin molded body on the resin molded body holding portion of the movable member is moved to the transfer surface of the mold. After pressing and transferring the transfer surface to the surface of the resin molded body, the gas in the second sealed tank is depressurized, and the movable member is moved away from the transfer surface of the mold, The resin molded body is peeled off from the transfer surface.

The invention of claim 9 is the method for producing a resin molded article according to claim 8,
During the process of transferring the transfer surface of the mold to the surface of the resin molded body and the process of peeling the resin molded body from the transfer surface of the mold, the internal temperature of the first sealed tank is maintained at a constant temperature. It is characterized by that.

  According to the present invention, the other end (pressing portion) of the movable member is accommodated in a second sealed tank connected to the first sealed tank via an intermediate wall, and the intermediate part of the movable member is the intermediate wall. The pressing means is attached to the intermediate wall so as to be movable, and the pressing means presses the other end (pressing portion) of the movable member by the pressure of the gas supplied into the second sealed tank to A pressing means for moving, by moving the movable member and transferring the transfer surface of the mold to the surface of the resin molded body held on the resin molded body holding portion, thereby producing a resin molded product, Resin that can accurately transfer a mold transfer surface with a fine concavo-convex pattern formed on the surface of a molded resin in a short time without using a complicated driving device for driving while maintaining the high pressure of carbon dioxide gas To provide a manufacturing apparatus and a manufacturing method for manufacturing a molded product It is possible.

  The present inventor uses a plasticizing effect generated by dissolving carbon dioxide gas in a resin to transfer a transfer surface on which a fine concavo-convex pattern or an optical mirror surface is formed to the surface of the resin molded body. When manufacturing products, a mold transfer surface with a fine uneven pattern formed on the surface of the resin molded body in a short time without using a complicated drive device to drive while maintaining the high pressure of carbon dioxide gas. Various studies were made on methods for producing resin molded products that can be transferred with high accuracy.

  As a result, when high-pressure carbon dioxide gas is injected into the sealed container to plasticize the surface of the resin molded body and transfer the mold transfer surface with a fine uneven pattern formed on the surface of the resin molded body with high accuracy. The sealed container is divided into first and second sealed tanks by an intermediate wall, and a movable member that presses the resin molded body against the transfer surface is movable in the first and second sealed tanks. If it was set as the manufacturing apparatus, it was thought that it was not necessary to form the movable part which leaks a carbon dioxide gas outside a sealed tank, and high pressure could be reliably maintained with a simple structure.

  That is, the movable member is a resin molded body holding portion that holds the resin molded body to which the transfer surface of the mold having one transfer surface is transferred, and the other end faces the movable member toward the transfer surface of the mold. It is a pressing part to be pressed, and has a structure in which the resin molded body holding part and the pressing part are coupled at the central part. Here, the resin molded body holding part is arranged in the first sealed tank together with the mold having the transfer surface, the pressing part is arranged in the second sealed tank, and the central part is movable through the intermediate wall. The member is arranged to be movable toward the mold transfer surface or away from the mold transfer surface. In addition, the resin molded body holding part is limited to movement in the first sealed tank, and the pressing part is limited to movement in the second sealed tank.

  Then, carbon dioxide gas is supplied into the first and second sealed tanks, and the surface of the resin molded body held by the resin molded body holding portion is plasticized with carbon dioxide gas in the first sealed tank. At the same time, by adjusting the pressure of the carbon dioxide gas in the first and second sealed tanks, the movable member is moved, the resin molded body is pressed against the mold transfer surface, and then peeled off. Therefore, without using a complicated drive device to drive while maintaining the high pressure of carbon dioxide gas, the mold transfer surface with a fine concavo-convex pattern formed on the surface of the resin molding can be obtained with high accuracy in a short time. It has been determined that it is possible to produce a resin molded product that can be transferred, and the present invention has been completed.

  Embodiments according to the present invention will be described below with reference to the drawings.

  FIG. 1 is a cross-sectional view showing the structure of a resin used in an embodiment according to the present invention, where (a) is a view showing a resin molded body before fine pattern transfer, and (b) is a resin molded product after pattern transfer. FIG. In the present embodiment, a sheet-shaped resin molded body 101 having a thickness of 1 mm obtained by molding a polymethyl methacrylate resin (hereinafter, PMMA: softening temperature 105 ° C.) as shown in FIG. Then, a mold transfer surface on which an L & S (line and space) pattern having a pitch of 2 μm and a depth of 1 μm is pressed against the surface of the resin molded body 101 to be transferred, and resin molding as shown in FIG. A resin molded product 103 in which the uneven pattern 102 was transferred to the surface of the body 101 was produced. Here, in order to distinguish between the resin before transfer shown in FIG. 1A and the resin after transfer shown in FIG. The product with the mold transfer surface transferred is referred to as a resin molded product 103.

  As shown in FIG. 1A, the resin molded body 101 used in the present invention does not need to be formed with a fine pattern, but has a substantially final shape, that is, a portion other than a portion to which the fine pattern is transferred. May be the final shape. Therefore, the resin molded body 101 can be easily manufactured at a low cost without any special device. Furthermore, the resin molded body 101 can be produced in parallel with the fine pattern transfer step, and an increase in the molding cycle due to an increase in the number of steps does not occur.

  Further, in the present invention, the resin molded body 101 is not limited to the PMMA, and is optional, and a thermoplastic resin such as a polycarbonate resin, a polymethyl methacrylate resin, a cycloolefin resin, a polyethylene resin, a polystyrene resin, or a polyester resin is selected. be able to. In this case, the resin molded body 101 is a single layer of the thermoplastic resin, formed of a plurality of layers made of different materials of these resins, or the surface of a curable resin is covered with the thermoplastic resin. Goods etc. can be used appropriately. Further, the shape is not limited to a sheet shape, and various shapes such as a plate shape and a lens shape can be employed.

  Next, the resin molded product manufacturing apparatus according to the first embodiment of the present invention will be described with reference to FIGS. FIG. 2 is a cross-sectional view showing a schematic configuration of a resin molded product manufacturing apparatus according to the first embodiment of the present invention. The manufacturing apparatus 1 according to the present embodiment presses the resin molded body 101 against a transfer surface 3 having a fine concavo-convex pattern (L & S pattern) formed on the surface of the mold 2 in a high-pressure carbon dioxide gas atmosphere. The resin molded body 101 can be peeled from 3.

  Specifically, a metal sealed container 4 capable of sealing high-pressure carbon dioxide gas is prepared, and the sealed container 4 is formed by an intermediate wall 5 formed of a metal material or a heat insulating material (for example, ceramics). It is divided into a first sealed tank 6 and a second sealed tank 7. A through hole 5a is formed at the center of the intermediate wall 5. The center 8a of the I-shaped movable member 8 passes through the through hole 5a, and the movable member 8 is vertically moved as indicated by an arrow. It is attached to be movable. One end of the movable member 8 in the first sealed tank 6 forms a resin molded body holding portion 9 that fixes and holds the resin molded body 101 and is accommodated in the first sealed tank 6. On the other hand, the mold 2 provided with the transfer surface 3 having the fine uneven pattern is fixed to the inner wall surface 6 a of the first sealed tank 6 facing the resin molded body holding portion 9 and accommodated in the first sealed tank 6. ing.

  The other end of the movable member 8 in the second sealed tank 7 forms a pressing portion 8b having a flat pressed surface 8b1 and is accommodated in the second sealed tank 7. And as shown in FIG. 2, the press part 8b is moved to the arrow direction with the gas pressure of the carbon dioxide gas supplied in the 2nd sealed tank 7, and with the movement of the press part 8b, the resin molding holding part 9 is also movable toward the transfer surface 3 of the mold 2 and away from the transfer surface 3.

  A first supply pipe 10 for supplying high-pressure carbon dioxide gas, a second supply pipe 11 and a first discharge pipe 12 for discharging carbon dioxide gas are respectively supplied to the first closed tank 6 and the second closed tank 7. The second discharge pipe 13 is connected. The first supply pipe 10 and the second supply pipe 11 are connected to one carbon dioxide cylinder 15 via one pressure booster 14. Further, the first supply pipe 10 and the second supply pipe 11 are respectively provided with a first supply valve 16 and a second supply valve 17 that can be opened and closed, and the first supply valve 16 and the second supply valve 17 are opened and closed. Accordingly, the carbon dioxide gas controlled to a predetermined pressure and temperature by the pressure intensifier 14 is appropriately supplied into the first sealed tank 6 and the second sealed tank 7, respectively. On the other hand, the first discharge pipe 12 and the second discharge pipe 13 have attachment ports, a first pressure-reducing valve 18 and a second pressure-reducing valve 18, respectively, capable of adjusting the pressure reduction rate of carbon dioxide gas in the first sealed tank 6 and the second sealed tank 7. A pressure reducing valve 19 is provided so that the gas pressure in the first sealed tank 6 and the second sealed tank 7 can be maintained at a constant pressure or reduced at a predetermined speed. In addition, a vacuum suction device 20 that can suck the gas in the second sealed tank 7 is connected to the second discharge pipe 13. Further, the outer wall portions 6b and 7b of the first sealed tank 6 and the second sealed tank 7 are appropriately adjusted to a predetermined temperature in the tanks in the first sealed tank 6 and the second sealed tank 7 respectively. A first temperature controller 21 and a second temperature controller 22 that can be maintained are provided. In the present embodiment, cartridge heaters are used as the first and second temperature controllers 21 and 22.

  In the present embodiment, the resin molded body 101 and the mold 2 are disposed in the first sealed tank 6, but may be disposed in the second sealed tank 7. Further, the mounting positions of the resin molded body 101 and the mold 3 may be reversed.

  Next, a method for producing a resin molded product using the production apparatus will be described with reference to FIG. FIG. 3 is a schematic diagram showing a process of manufacturing a resin molded product using the manufacturing apparatus according to the first embodiment of the present invention. FIG. 3A shows the inside of the first sealed tank 6 and the second sealed tank 7. It is a figure which shows the process of supplying a carbon dioxide gas to. FIG. 5B is a diagram showing a process of moving the movable member 8 and transferring the transfer surface 3 of the mold to the resin molded body 101, and FIG. 5C is a diagram in which carbon dioxide gas is released from the resin molded body 101 and solidified. The figure which shows a process, (D) is a figure which shows the process of peeling the resin molding 101 from the transfer surface 3 of a metal mold | die.

  In the method for manufacturing a resin molded product according to an embodiment of the present invention, manufacturing is performed in the following order of steps (1) to (4).

(1) First, as shown in FIG. 3 (A), after the upper part of the first sealed tank 6 is opened and the resin molded body 101 is fixed on the resin molded body holding portion 9 at one end of the movable member 8, the first The carbon dioxide which was closed up above the first sealed tank 6 and then opened to the predetermined pressure by opening the first supply valve 16 and the second supply valve 17 in the first sealed tank 6 and the second sealed tank 7. A high-pressure carbon dioxide gas (CO ₂ ) is injected from the pressure intensifier 14 storing the gas. In this case, the supply amount is adjusted by the first supply valve 16 and the first supply valve 17 so that the pressure in the first sealed tank 6 is P1 = the pressure P2 in the second sealed tank 7. (In this case, since the first supply pipe 10 and the second supply pipe 11 are connected between the pressure increasing device 14 and the first and second supply valves 16 and 17, the first and second supply The valves 16 and 17 are both fully open.) As described above, since the pressure in the first sealed tank 6 is P1 = the pressure P2 in the second sealed tank 7, the movable member 8 is almost free. The surface of the resin molded body 101 and the transfer surface 3 of the mold 2 are not in contact with each other. As a result, the resin molded body 101 is plasticized by being impregnated with the carbon dioxide gas G from the surface thereof. Here, the temperature regulators 21, T2 and T2 in the first sealed tank 6 and the second sealed tank 7 are set to a desired temperature equal to or lower than the softening temperature of the resin molded body 101 resin used in advance. The temperature was raised at 22. Note that the temperature controllers 21 and 22 may be integrated temperature controllers without being independent of each other.

(2) Next, the first supply valve 16 is closed, only the second supply valve 17 is opened, and only the gas pressure in the second sealed tank 7 is further increased. At this time, since the pressure in the first sealed tank 6 is P1 <the pressure in the second sealed tank 7 is P2, the movable member 8 is pressed upward by the pressing portion 8b with the gas pressure P2 of the second sealed tank 7. It moves to the 1st sealed tank 6 side (arrow A direction). Along with the upward movement of the pressing portion 8b by the gas pressure of the movable member 8, the resin molded body 101 attached to the resin molded body holding portion 9 of the movable member 8 and whose surface is plasticized with carbon dioxide gas is a mold. 2 is brought into contact with the transfer surface 3, and a pressing force is applied to the plasticized resin molded body 101. As a result, the pattern formed on the transfer surface 3 of the mold is transferred to the surface of the resin molded body 101. At this time, the first pressure reducing valve 18 is adjusted so that the pressure in the first sealed tank 6 is maintained constant.

(3) Subsequently, the first pressure reducing valve 18 is opened, and the pressure in the first sealed tank 6 is reduced to atmospheric pressure, whereby the carbon dioxide gas G is released from the resin molded body 101 and solidified. In this case, since the gas pressure P2 in the second sealed tank 7 is higher than the gas pressure P1 in the first sealed tank 6, the resin molded body 101 is pressed against the transfer surface 3 by the gas pressure P2. The carbon dioxide gas G can be effectively released from the body 101.

(4) Furthermore, the second pressure reducing valve 19 is opened, and the carbon dioxide gas G in the second sealed tank 7 is sucked by the vacuum suction device 20 so that the pressure in the second sealed tank 7 is equal to or lower than the atmospheric pressure. Thus, the pressure in the first sealed tank 6: P1> the pressure in the second sealed tank 7: P2, and the movable member 8 is sucked and moved to the second sealed tank 6 side (arrow B), and the resin molded body 101 is peeled off from the transfer surface 3 of the mold. Thereafter, the upper part of the first sealed tank 6 is opened, and the resin molded body 101 having the fine pattern 102 transferred to the surface is taken out from the resin molded body holding portion 9 to obtain a resin molded product 103 (see FIG. 1B). be able to.

  In the above-described process, since the resin molded body 101 is plasticized and solidified by dissolving and releasing the carbon dioxide gas G in the resin molded body 101, the first sealed tank 6 and the second sealed tank 7 are used. The internal temperatures T1 and T2 need not be subjected to heating and cooling processes for the mold 2 and the resin molded body 101 between steps (1) to (4) as in the prior art, and are maintained at a constant temperature. It is possible to manufacture the resin molded product 103 sufficiently even if it is merely. Accordingly, since the heating and cooling processes are not required, it is possible to transfer and form a fine pattern with high accuracy on the surface of the resin molded body 101 in a short time.

  Incidentally, in the above embodiment, in the step (1), carbon dioxide gas having a gas pressure of 10 MPa and a temperature of 40 ° C. is injected into the first sealed tank 6 and the second sealed tank 7, and is injected into the resin molded body 101. Carbon dioxide gas was dissolved. In addition, it maintained by the temperature regulators 21 and 22 so that the temperature in the 1st sealed tank 6 and the 2nd sealed tank 7 at this time might also be 40 degreeC.

  In step (2), only the second sealed tank 7 is increased to 15 MPa, the movable member 8 is moved in the direction of the first sealed tank 6 (direction A), and the resin molded body 101 is transferred to the mold transfer surface. 3 was pressed for about 30 seconds. At this time, although the volume of the first sealed tank 6 and the second sealed tank 7 changed, the first pressure reducing valve 18 was adjusted so that the pressure in the first sealed tank 6 was not changed. On the other hand, the temperature of the 1st sealed tank 6 and the 2nd sealed tank 7 is always fixed at 40 degreeC. Thereafter, in step (3), the first sealed tank 6 was depressurized to atmospheric pressure, whereby carbon dioxide gas was released from the resin molded body 101 and solidified. Next, in the step (4), the carbon dioxide gas G in the second sealed tank 7 is sucked by the vacuum suction device 20, the gas pressure in the second sealed tank 7 is reduced to the atmospheric pressure or lower, and the movable member 8 is moved. The resin molded body 101 was peeled from the transfer surface 3 of the mold 2 by sucking and moving in the direction of the second sealed tank 7 (arrow B). FIG. 4 shows the result of measuring the transfer result at this time using an AFM (atomic force microscope). As is clear from this result, the fine unevenness pattern A on the transfer surface 3 of the mold and the fine unevenness pattern B of the resin molded product 103 are almost 100% identical, and the resin molding is performed on the transfer surface 3 of the mold. It can be seen that the body 101 is filled to every corner.

  In the present embodiment, by using the plasticizing effect due to the dissolution of the carbon dioxide gas in the resin molded body 101, a fine uneven pattern can be accurately transferred onto the resin surface. In this case, since the mold temperature does not become higher than the softening temperature of the resin used and can be transferred at a constant temperature (40 ° C. in this embodiment), the carbon dioxide gas G is dissolved and maintained. The molding time of the process from the step (1) to the step (4) of releasing and releasing was able to be transferred in a very short time of 5 minutes or less.

  Further, since the gas pressure of carbon dioxide gas is used, a special driving device as a means for pressing the resin molded body 101 against the transfer surface 3 of the mold 2 is unnecessary, and the device itself has a compact configuration. And low cost. Moreover, since the movable member 8 moves within the sealed container 4, it is possible to easily maintain a high pressure and to move the movable member 8 while applying a sealing force while applying a pressing force. The speed and pressing force during pressing can be adjusted as appropriate by adjusting the gas pressure in the second sealed tank 7 with the first supply valve 16, the second pressure reducing valve 19, the second supply valve 17, and the like. Further, since the movable member 8 is moved and pressed using the gas pressure, the pressure can be uniformly applied to the transfer surface 3 of the mold 2.

  In the above-described embodiment, the carbon dioxide gas G supplied into the first sealed tank 6 is used as a gas supplied into the second sealed tank 7 by being distributed from one pressure booster 14. However, the carbon dioxide gas G may be supplied using a pressure booster independent of the carbon dioxide gas G supplied into the first sealed tank 6. Further, as the gas supplied into the second sealed tank 7, it is possible to use a gas different from carbon dioxide gas such as air or nitrogen gas. However, when the carbon dioxide gas G distributed from the carbon dioxide gas G supplied into the first sealed tank 6 is used as the gas supplied into the second sealed tank 7, the center of the movable member 8 is used. Even if the gas in the second sealed tank 7 leaks into the first sealed tank 6 due to the clearance between the portion 8a and the through-hole 5a of the intermediate wall 5, the resin molded body 101 is adversely affected by plasticization by the carbon dioxide gas. Can be suppressed, which is preferable.

  In the said embodiment, the carbon dioxide gas of the same pressure is inject | poured into the 1st sealed tank 6 and the 2nd sealed tank 7, and the resin molding 101 arrange | positioned at the 1st sealed tank 6 is made to impregnate a carbon dioxide gas. I am doing so. Thus, by injecting carbon dioxide gas of the same pressure into the first sealed tank 6 and the second sealed tank 7, a desired gas pressure can be maintained and the resin molded body 101 can be plasticized reliably.

  Moreover, in the said embodiment, when it is set as the gas pressure P1 of the carbon dioxide gas in the 1st airtight tank 6, and the carbon dioxide gas pressure P2 in the 2nd airtight tank 7, it is P1 <P2. 8 is moved in the direction of the first sealed tank 6, the resin molded body 101 and the transfer surface 3 of the mold are brought into contact with each other, a pressing force is applied, and then the resin molded body 101 and the transfer surface of the mold are set as P1> P2. 3 is peeled off. As described above, since the movable member 8 is moved in the sealed container 4 by changing the gas pressure in the first sealed tank 6 and the second sealed tank 7, the high pressure is easily maintained and the sealing performance is improved. The movable member 8 can be moved while securing the pressing force to the resin molded body 101.

  In the above embodiment, the first and second sealings are performed during the process of pressing the resin molded body 101 against the transfer surface 3 of the mold and transferring the resin molded body 101 from the transfer surface 3 of the mold. The internal temperature of the tanks 6 and 7 is constant. In this way, since the heating and cooling process steps of the resin molded body 101 and the mold 2 that are conventionally performed in order to appropriately transfer the transfer surface to the resin molded body 101 are not required, the processing is performed in a very short molding time. be able to.

  As described above, in the above-described embodiment, the sealed container 4 capable of injecting high-pressure carbon dioxide gas is divided into the first sealed tank 6 and the second sealed tank 7 by the fixed intermediate wall 5, and the first sealed The gas pressure of carbon dioxide gas in the tank 6 and the second sealed tank 7 is adjusted to move the movable member 8 disposed through the intermediate wall 5 and press the resin molded body 101 against the transfer surface 3 of the mold. Thus, the mold transfer surface 3 is transferred onto the surface of the resin molded body 101. As a result, there is no need for an expensive special structure driving device as a means for pressing the resin molded body 101 against the transfer surface 3 of the mold, and the manufacturing apparatus itself is made compact and low-cost. Can do.

  Next, a resin molded product manufacturing apparatus according to a second embodiment of the present invention will be described with reference to FIGS. FIG. 5: is sectional drawing which shows schematic structure of the manufacturing apparatus of the resin molded product which concerns on 2nd Embodiment by this invention. FIG. 6 is a schematic diagram showing a process of manufacturing a resin molded product using the manufacturing apparatus according to the second embodiment of the present invention. FIG. 6A shows the inside of the first sealed tank 6 and the second sealed tank 7. It is a figure which shows the process of supplying a carbon dioxide gas to. (B) is a figure which shows the process of peeling a resin molding from the transfer surface of a metal mold | die.

  The manufacturing apparatus according to the second embodiment differs from the manufacturing apparatus according to the first embodiment described above with reference to the area S1 of the holding surface 9a of the resin molded body holding portion 9 of the movable member 8, as shown in FIG. The area S2 of the pressed surface 8b1 of the pressing portion 8b is different and is configured to satisfy S1 <S2, and between the intermediate wall 5 on the second sealed tub 7 side and the pressing portion 8b of the movable member 8. Is different in that an elastic member 23 having a through hole 23a penetrating the central portion 8a of the movable member 8 is disposed at the central portion.

  In this way, by setting the area S1 of the holding surface 9a of the resin molded body holding part 9 of the movable member 8 and the area S2 of the pressed surface 8b1 of the pressing part 8b to S1 <S2, FIG. As shown, when the high pressure carbon dioxide gas G having the same pressure: P is injected into the first sealed tank 6 and the second sealed tank 7, the load F1 loaded on S1 and the load F2 loaded on S2 are: F1 = P × S1 and F2 = P × S2, respectively. That is, since F1 <F2, the elastic member 23 is compressed, and the movable member 8 is moved in the direction (A direction) of the first sealed tank (6), so that the resin molded body holding portion 9 of the movable member 8 is obtained. It is possible to transfer the transfer surface 3 to the surface of the resin molded body 101 with high accuracy by pressing the resin molded body 101 fixed on the transfer surface 3 formed on the mold 2.

  In this case, the elastic member 23 disposed between the intermediate wall 5 and the pressing portion 8b of the movable member 8 is moved in the middle by moving the movable member 8 in the direction (A direction) of the first sealed tank (6). The wall 5 and the pressing portion 8b of the movable member 8 are sandwiched and compressed. Thereafter, as shown in FIG. 6B, the first pressure reducing valve 18 and the second pressure reducing valve 19 were opened, and the first sealed tank 6 and the second sealed tank 7 were compressed to atmospheric pressure. By the force that the elastic member 23 recovers, the movable member 8 is forcibly moved in the direction (B) of the second sealed tank 7, and the resin molded body 101 can be appropriately separated from the transfer surface 3 formed on the mold 2. it can.

  Thus, in this 2nd Embodiment, it is not necessary to control the pressure of the carbon dioxide gas of the 1st sealed tank 6 and the 2nd sealed tank 7 separately, and the movable member 8 can be pushed and moved by the same pressure. It becomes possible. Furthermore, since the peeling operation can be appropriately performed by the recovery force of the elastic member, the manufacturing apparatus 1 can be greatly simplified and reduced in cost. Further, since the first sealed tank 6 and the second sealed tank 7 are always at the same pressure, even if there is a clearance on the sliding surface between the intermediate wall 5 and the movable member 8, the pressure in the first sealed tank 6 Can be reliably maintained. Even when the resin molded body 101 is peeled off from the transfer surface 3 formed on the mold 2, it can be carried out only by reducing the pressure without controlling the pressure by the recovery force of the elastic member 23. In the present embodiment, the pressing force can be arbitrarily changed by changing the area ratio of S1 and S2 or returning the material (hardness) of the elastic member 23.

  Incidentally, in this 2nd Embodiment, although the silicone resin which is a thermosetting resin was used as the elastic member 23, it is not limited to this.

  Next, a resin molded product manufacturing apparatus according to a third embodiment of the present invention will be described with reference to FIG.

  In the third embodiment, the manufacturing apparatus shown in FIG. 1 is used, but the temperature of the first sealed tank 6 and the second sealed tank 7 is controlled separately, and the temperature regulators 21 and 22 are used. Yes. And the inside temperature of the 1st airtight tank 6 and the 2nd airtight tank 7 is controlled so that it may differ, and the movable member 8 is moved based on the temperature difference in an inside tank.

  That is, in this 3rd Embodiment, after inject | pouring the high pressure carbon dioxide gas of the same pressure into the 1st airtight tank 6 and the 2nd airtight tank 7, it is the inside of the tank in the 1st airtight tank 6 by the temperature regulators 21 and 22. The temperature T1 and the temperature T2 in the second sealed tank 7 are controlled separately so that T1 <T2. Since the temperature T2 in the second sealed tank 7 is higher than the temperature T1 in the first sealed tank 6, even when carbon dioxide gas of the same pressure is injected, the second sealed is set so that the temperature in the tank is increased. In the tank 7, the movable member 8 moves in the direction of the first sealed tank 6 so that the carbon dioxide gas expands and the volume of the second sealed tank increases.

  As a result, the resin molded body 101 disposed in the first sealed tank 6 and the transfer surface 3 formed on the mold 2 come into contact with each other, and a pressing force can be applied to the resin molded body 101. Thereafter, as in the case of the first embodiment, the second pressure reducing valve 19 is opened, and the pressure in the second sealed tank 7 is reduced to the atmospheric pressure or less by the vacuum suction device 20, whereby the resin molded body 101. And the transfer surface 3 can be peeled off. Also in this embodiment, the first sealed tank 6 and the second sealed tank 7 are controlled separately and independently, but the temperatures T1 and T2 of each tank are for softening and curing the resin molded body. It is not necessary to perform heating and cooling during the process. As a result, since the resin molded body 101 is plasticized with carbon dioxide gas, the tank internal temperatures T1 and T2 can be transferred at a relatively low temperature and can be processed in a short time.

  Even if the carbon dioxide gas in the second sealed tank 7 is not vacuumed, the temperature of the first sealed tank 6 and the second sealed tank 7 is reversed as T1> T2, thereby moving the movable member 8 to the second sealed tank. It is also possible to move in the direction 7 and peel off. In this case, the vacuum suction device 20 becomes unnecessary.

  In the case of the third embodiment, the pressure of the carbon dioxide gas in the first sealed tank 6 and the second sealed tank 7 is set to the first and second supply valves 16 and 17 and the first and second pressure reducing valves 18 and 19. Thus, it is not necessary to individually control the pressure, and the pressing force and the speed thereof can be controlled only by changing the temperature in the first sealed tank 6 and the second sealed tank 7.

  Moreover, in this 3rd Embodiment, it is desirable to form the intermediate | middle wall 5 which has divided | segmented the 1st sealed tank 6 and the 2nd sealed tank 7 with heat insulation members, such as a ceramic material. Thereby, heat transfer from the first sealed tank 6 to the second sealed tank 7 can be reduced, and the temperatures can be controlled independently and accurately, and a reliable operation can be performed.

  About 1st-3rd embodiment by this invention demonstrated so far, it is also possible to implement any two combination or combining three. Further, the shape of the fine pattern shown in each embodiment is not limited to application to transfer, and it goes without saying that various modifications are possible without departing from the spirit of the transfer, for example, transfer to an optical mirror surface. .

It is sectional drawing which shows the structure of resin used by one Embodiment by this invention, (a) is a figure which shows the resin molding before fine pattern transfer, (b) is a figure which shows the resin molded product after pattern transfer. is there. It is sectional drawing which shows schematic structure of the manufacturing apparatus of the resin molded product which concerns on 1st Embodiment by this invention. It is a schematic diagram which shows the process of manufacturing a resin molded product using the manufacturing apparatus which concerns on 1st Embodiment by this invention, (A) is carbon dioxide gas in the 1st sealed tank 6 and the 2nd sealed tank 7 FIG. 4B is a diagram showing a process of raising the movable member and transferring the transfer surface of the mold to the resin molded body, and FIG. The figure which shows the process made to solidify, (D) is a figure which shows the process of peeling a resin molding from the transfer surface of a metal mold | die. It is the graph which measured the cross-sectional depth of the transfer surface of a resin molded product and a metal mold | die using the manufacturing apparatus which concerns on 1st Embodiment by this invention. It is sectional drawing which shows schematic structure of the manufacturing apparatus of the resin molded product which concerns on 2nd Embodiment by this invention. It is a schematic diagram which shows the process of manufacturing a resin molded product using the manufacturing apparatus which concerns on 1st Embodiment by this invention, (A) is carbon dioxide gas in the 1st sealed tank 6 and the 2nd sealed tank 7 It is a figure which shows the process of supplying. (B) is a figure which shows the process of peeling a resin molding from the transfer surface of a metal mold | die.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 2 Mold 3 Transfer surface 4 Sealed container 5 Middle wall 6 1st sealed tank 7 2nd sealed tank 8 Movable member 8a Center part 8b Press part 8b1 Pressed surface 9 Resin molded object holding part 10 1st supply pipe 11 Second supply pipe 12 First discharge pipe 13 Second discharge pipe 14 Pressure booster 15 Carbon dioxide cylinder 16 First supply valve 17 Second supply valve 18 First pressure reducing valve 19 Second pressure reducing valve 20 Vacuum suction device 21, 22 Temperature Adjuster 23 Elastic member 101 Resin molded body 102 Concavity and convexity pattern 103 Resin molded product

Claims (9)

A mold having at least one transfer surface; and a resin molded body holding portion that is disposed to face the transfer surface of the mold and holds a resin molded body to which the transfer surface of the mold is transferred. A first sealed tank to be accommodated, a movable member having the resin molded body holding portion at one end, the resin molded body holding portion being movably attached to a transfer surface of the mold, and one end of the movable member A pressing means that presses the pressing portion that is the other end opposite to the transfer surface of the mold, a supply port that supplies carbon dioxide gas to be impregnated into the resin molded body in the first sealed tank, and An apparatus for producing a resin molded product having a discharge port for discharging carbon dioxide gas from the first sealed tank,
The other end of the movable member is accommodated in a second sealed tank connected to the first sealed tank via an intermediate wall,
An intermediate portion between the resin molded body holding portion and the pressing portion of the movable member is attached to the intermediate wall so as to be movable through the intermediate wall,
The pressing means is a pressing means that moves the movable member by pressing the pressing portion of the movable member by the pressure of the gas supplied into the second sealed tank.
Manufacturing the resin molded product, wherein the movable member is moved to transfer the transfer surface of the mold onto the surface of the resin molded product held on the resin molded product holding part. apparatus. In the manufacturing apparatus of the resin molded product according to claim 1,
The gas supplied to the second sealed tank is carbon dioxide gas, and the carbon dioxide gas having the same pressure as the carbon dioxide gas supplied to the first sealed tank is supplied to supply the carbon dioxide gas to the resin molding. An apparatus for producing a resin molded product, characterized by being impregnated. In the manufacturing apparatus of the resin molded product according to claim 1 or 2,
When the gas pressure of the carbon dioxide gas supplied to the first sealed tank is P1, and the gas pressure of the gas supplied to the second sealed tank is P2, the pressure of the movable member is set by P2> P1. The movable member is moved so as to separate and peel the resin molded body from the transfer surface of the mold by pressing the part, pressing the resin molded body against the transfer surface of the mold, and setting P2 <P1. An apparatus for producing a resin molded product, characterized in that: In the manufacturing apparatus of the resin molded product according to any one of claims 1 to 3,
When the area of the resin molded body holding surface of the resin molded body holding portion of the movable member is S1, and the area of the pressed surface of the pressing portion of the movable member is S2, the relationship between S1 and S2 is S1 < The apparatus for producing a resin molded product, which is S2. In the manufacturing apparatus of the resin molded product according to any one of claims 1 to 4,
An elastic member is disposed between the intermediate wall and the pressing portion of the movable member, and gas is supplied into the second sealed tank so that the pressing portion of the movable member faces the transfer surface of the mold. When moved, when the elastic member is pressed and the pressure of the gas in the second sealed tank is reduced, the elastic recovery force of the elastic member causes the elastic member on the resin molded body holding portion of the movable member. An apparatus for producing a resin molded product, wherein the resin molded body is peeled off from the transfer surface of the mold. In the manufacturing apparatus of the resin molded product according to any one of claims 1 to 5,
The first sealed tank and the second sealed tank are provided with first and second temperature control devices for controlling the temperature in each tank, respectively, and gas of equal pressure is supplied to the first sealed tank and the second sealed tank. In this case, the first and second temperature control devices are controlled so that T1 <T2 when the tank temperature T1 of the first sealed tank and the tank temperature T2 of the second sealed tank are set. As the gas in the second sealed tank expands, the movable member is moved and the resin molded body on the resin molded body holding portion of the movable member is pressed against the transfer surface of the mold to transfer the mold. An apparatus for producing a resin molded product, wherein the surface is transferred to the surface of the resin molded body. In the manufacturing apparatus of the resin molded product according to any one of claims 1 to 6,
The said intermediate wall is formed with the heat insulation member, The manufacturing apparatus of the resin molded product characterized by the above-mentioned. Carbon dioxide gas is supplied into a first sealed tank containing a mold having at least one transfer surface and a resin molded body, and the resin molded body is impregnated with the carbon dioxide gas, and then the mold is molded. In the method for manufacturing a resin molded product, the surface of the resin molded body is pressed against the transfer surface of the resin, and the transfer surface is transferred to the surface of the resin molded body
Using the apparatus for producing a resin molded product according to any one of claims 1 to 7,
Gas is supplied into the second sealed tank to move the movable member toward the transfer surface of the mold, and the resin molded body on the resin molded body holding portion of the movable member is moved to the transfer surface of the mold. After pressing and transferring the transfer surface to the surface of the resin molded body, the gas in the second sealed tank is depressurized, and the movable member is moved away from the transfer surface of the mold, A method for producing a resin molded product, comprising peeling the resin molded body from the transfer surface. In the manufacturing method of the resin molded product of Claim 8,
During the process of transferring the transfer surface of the mold to the surface of the resin molded body and the process of peeling the resin molded body from the transfer surface of the mold, the internal temperature of the first sealed tank is maintained at a constant temperature. A method for producing a resin molded product, characterized by comprising:

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