JP2013135107A - Mold and method for molding article to be molded - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate removal of a residual film in a method for molding an article to be molded in which a photosetting material is molded by transferring a fine transfer pattern formed on a mold to the photosetting material.SOLUTION: A method for molding an article to be molded comprises the steps of: providing an uncured molding material 17 on a base material 11; installing a mold 1 having a substrate 3 composed of a light transmissive material and a plurality of fine recesses 7 composed of a light-shielding material so that a transfer pattern 5 of the mold 1 adheres tightly to the uncured molding material 17; curing a part 17B of the molding material 17 by irradiating the molding material 17 with light through the substrate 3 of the mold 1; separating the mold 1 from the molding material 17; and removing an uncured molding material 17A.

Description

  The present invention relates to a mold and a molding method of a molded article, and for example, relates to a mold for forming a fine pattern of an ultraviolet curable resin using a mold.

  Conventionally, a molding method (transfer method) for forming an ultraviolet curable resin by providing a thin film of uncured ultraviolet curable resin on one surface of a substrate and transferring a fine transfer pattern of the mold onto the ultraviolet curable resin. Is known (see, for example, Patent Document 1).

JP 2009-208316 A

However, in the conventional molding method, if the mold is removed from the ultraviolet curable resin after the ultraviolet curable resin is cured, a thin residual film remains on the substrate. If this residual film is removed by O ₂ ashing or the like, there is a problem that a long time is required for the removal.

  The remaining film is composed of a cured ultraviolet curable resin, and is formed between each fine convex portion (cured ultraviolet curable resin) formed by transfer, and covers the substrate very thinly. It is.

  The present invention has been made in view of the above problems, and a molding method for a molded product for molding the photocurable material by transferring a fine transfer pattern formed on a mold onto the photocurable material, and An object of the present invention is to provide a mold in which the remaining film can be easily removed.

  The invention according to claim 1 is a plurality of substrates that are made of a material that transmits light and a material that blocks light, and are provided on one surface in the thickness direction of the substrate so as to be separated from each other. A mold having a transfer pattern formed with fine convex portions.

  The invention described in claim 2 is an uncured molding material installation step in which a base material is provided with an uncured molding material that is cured by light irradiation, a substrate made of a material that transmits light, and light. The transfer pattern of a mold having a transfer pattern formed of a plurality of fine protrusions formed of a material to be shielded and formed on one surface in the thickness direction of the substrate so as to be separated from each other is provided. A mold installation process for installing the mold on the molding material so as to be in close contact with the uncured molding material installed in the molding material installation process, and the mold is installed on the molding material in the mold installation process. Thereafter, the molding material is cured by irradiating the molding material with light through the substrate of the mold to cure a part of the molding material, and a part of the molding material is cured in the molding material curing process. Thereafter, the mold is separated from the molding material. A step, after releasing the mold from the object molding material in the mold separating process, a molding method of the molded article having an uncured the molded material removal step of removing the object to be molded uncured material.

  According to the present invention, in the molding method and mold of a molded product for molding the photocurable material by transferring the fine transfer pattern formed on the mold to the photocurable material, it is easy to remove the remaining film. There is an effect that there is.

It is a figure which shows schematic structure of a type | mold. It is a figure which shows the state which has installed the type | mold to the to-be-molded body and has irradiated the ultraviolet-ray. It is a figure which shows the state which isolate | separated the type | mold from the to-be-molded body, after hardening a part of ultraviolet curable resin. It is a figure which shows the to-be-molded product obtained by removing uncured ultraviolet curing resin.

  A mold 1 according to an embodiment of the present invention includes a substrate (base material) 3 and a transfer pattern 5 as shown in FIG. The substrate 3 is made of a material that transmits light and is formed in a plate shape. For example, the substrate 3 is made of quartz glass that transmits ultraviolet light and has a rectangular flat plate shape.

  The transfer pattern 5 is formed by a plurality of fine convex portions 7. The convex portions 7 are integrally provided on one surface in the thickness direction of the substrate 3 with a slight distance from each other. Moreover, the convex part 7 is comprised with the material which interrupts | blocks light (for example, ultraviolet-ray) (light does not permeate | transmit).

  The convex part 7 is formed in a fine rectangular parallelepiped shape. The height of the convex portion 7 (the vertical dimension in FIG. 1), the horizontal dimension (the horizontal dimension in FIG. 1), the vertical dimension (the dimension in the direction perpendicular to the plane of FIG. 1), and each other The distance between the convex portions 7 adjacent to each other (the dimension in the left-right direction in FIG. 1) is, for example, the same size as the wavelength of visible light. Moreover, the height dimension of the convex part 7 is larger than the horizontal dimension or the vertical dimension of the convex part 7.

  As a result, a plurality of columnar convex portions 7 (transfer patterns 5) are formed in the form of dots and spaces on one surface in the thickness direction of the substrate 3 (the upper surface of the substrate 3 in FIG. 1). Become. In addition, each convex part 7 may be formed in the form of a line & space. Moreover, the board | substrate 3 is exposed and exposed in the place where the convex part 7 is not provided (between each convex part 7 which mutually adjoins). That is, in the mold 1, the remaining film 8 as shown in FIG.

  In FIG. 1, the transfer pattern 5 is provided on the entire surface of the substrate 3, but the transfer pattern 5 may be provided on a part of the substrate 3. For example, the transfer pattern 5 may be provided only at the center of one surface of the substrate 3 in the thickness direction, or may be provided only at the periphery of one surface of the substrate 3 in the thickness direction. It may be configured as described above.

  Each projection 7 is generated by maskless lithography, but may be generated by transfer as described in Patent Document 1 (Japanese Patent Laid-Open No. 2009-208316). However, it may be generated by photolithography and etching.

  Further, an opaque synthetic resin (for example, an ultraviolet curable resin mixed with black ink) or the like is employed as a material that blocks light constituting the convex portion 7.

  In the mold 1, instead of the ultraviolet curable resin, a thermosetting resin or a thermoplastic resin may be adopted as each convex portion 7 by transfer. And each convex part 7 may be produced | generated at temperature higher than normal temperature, or normal temperature.

  As illustrated in FIG. 4, the molded product 9 includes a base material (substrate) 11 and a molded body 13. The substrate 11 is made of, for example, a PET film (a material formed into a rectangular flat plate shape using polyethylene terephthalate).

  The to-be-molded body 13 is comprised with the hardened photocurable resin (for example, ultraviolet curable resin). The molded body 13 is formed with a plurality of fine convex portions 15. The protrusions 15 are integrally provided on one surface in the thickness direction of the substrate 11 so as to be separated from each other.

  Although described in detail later, the molded body 13 is formed by transferring the transfer pattern 5 of the mold 1.

  Therefore, the convex portion 15 of the molded body 13 is formed in a fine rectangular parallelepiped shape. The height of the convex portion 15 (the vertical dimension in FIG. 4), the horizontal dimension (the horizontal dimension in FIG. 4), the vertical dimension (the dimension in the direction perpendicular to the plane of FIG. 4), and each other The distance between the convex portions 15 adjacent to each other (dimension in the left-right direction in FIG. 4) is, for example, the same size as the wavelength of visible light, similarly to each convex portion 7 shown in FIG. Yes.

  Moreover, in the place where the convex part 15 is not provided (between each convex part 15 which mutually adjoins), the base material 11 is exposed and exposed.

  In FIG. 4, the molded body 13 is provided on the entire surface of the base material 11, but in the same manner as in the case of the mold 1, the molded body 13 is provided on a part of the base material 11. There may be.

  Here, a method for forming the product 9 will be described.

  The molded product 9 is generated through, for example, an uncured molded material installation process, a mold installation process, a molded material curing process, a mold separation process, and an uncured molded material removal process.

  In the uncured molding material installation step, an uncured molding material (resin; for example, a photocurable material such as an ultraviolet curable resin) is cured on one surface in the thickness direction of the base material 11 by light irradiation. ) Is provided (not shown). The uncured molding material installed in the uncured molding material installation step has a thin film shape on one surface in the thickness direction of the flat substrate 11.

  In the mold installation step, as shown in FIG. 2, the mold 1 is placed on the ultraviolet curable resin 17 so that the transfer pattern 5 of the mold 1 is in close contact with the uncured ultraviolet curable resin 17 installed in the uncured molding material installation step. It is the process of installing in.

  The state in which the mold 1 is installed in the mold installation process will be further described. The thickness direction of the substrate 3 of the mold 1 and the thickness direction of the base material 11 of the finished product match each other. 11 are opposed to each other with a distance slightly larger than the height value of the convex portion 7 of the transfer pattern 5.

  In the state shown in FIG. 2, for example, the mold 1 is biased downward. Thereby, the uncured ultraviolet curable resin 17 is sandwiched between the mold and the substrate 11 and pressed with a predetermined force.

  In spite of the above pressing, in the state shown in FIG. 2, an uncured UV curable resin 17 is very small between the tip (the lower end in FIG. 2) of the mold 1 and the substrate 11. A thin portion 17A exists. This portion 17A is a portion that becomes a remaining film by conventional transfer.

  In the molding material curing step, as shown in FIG. 2, the mold 1 is placed on the ultraviolet curable resin 17 (the base material 11 provided with the ultraviolet curable resin 17) in the mold installation step, and then passed through the substrate 3 of the mold 1. This is a step of irradiating the molding material 17 with light (for example, ultraviolet rays) to cure a part (part irradiated with light) 17B of the ultraviolet curable resin 17.

  Ultraviolet rays are generated by an ultraviolet ray generator 19 installed above the mold 1. Ultraviolet rays (for example, parallel rays) emitted from the ultraviolet ray generator 19 pass through the substrate 3 of the mold 1 and are applied to the ultraviolet curable resin 17. However, not all the portions of the ultraviolet curable resin 17 are irradiated with ultraviolet rays. That is, since the convex portion 7 provided in the mold 1 blocks the ultraviolet rays, the ultraviolet rays emitted by the ultraviolet ray generator 19 are applied to the portions (for example, a rectangular parallelepiped portion) 17B existing between the convex portions 7. Is irradiated, but the aforementioned portion 17A is not irradiated.

  Thereby, in the molding material curing step, the portion 17B of the ultraviolet curable resin 17 is cured, and the portion 17A is not cured.

  The mold separation process is a process of separating the mold 1 from the molding material 17 after curing a part 17B of the ultraviolet curable resin in the molding material curing process. When the mold 1 is separated from the material to be molded 17 in the mold separation process, it is as shown in FIG. In FIG. 3, a molded body 13 (each convex portion 15; a cured ultraviolet curable resin 17 </ b> B) is formed on one surface in the thickness direction of the base material 11. Further, a very thin uncured ultraviolet curable resin 17A exists between the convex portions 15 and at the bottom (base end) of each convex portion 15.

  The uncured molding material removing step is a step of removing the uncured ultraviolet curable resin 17A after releasing the mold 1 from the ultraviolet curable resin 17 in the mold separation step. The uncured ultraviolet curable resin 17A is removed by dissolving the uncured ultraviolet curable resin 17A in, for example, a solvent (a solvent that does not dissolve the cured ultraviolet curable resin 17B).

According to the molding method of the molded product, the residual film 17A remaining on the molded product 9 is uncured, so that the residual film can be easily removed. Further, since the uncured residual film 17A is removed, the portion 17B that should not be removed originally (photocuring) compared to the case where the cured residual film is removed by ashing (O ₂ ashing) or the like as in the prior art. It is possible to substantially eliminate the damage and omission of the convex portion 15) hardened with the functional material.

DESCRIPTION OF SYMBOLS 1 type | mold 3 board | substrate 5 transfer pattern 7 convex part 9 molded product 11 base material 17 uncured molding material 17A site | part of the molding material which does not harden 17B site | part of the molding material which hardens | cures

Claims (2)

A substrate made of a material that transmits light;
A transfer pattern formed of a plurality of fine convex portions that are made of a material that blocks light and are provided apart from each other on one surface in the thickness direction of the substrate;
A mold characterized by having. An uncured molding material installation step for providing a base material with an uncured molding material that is cured by light irradiation;
A transfer pattern formed of a substrate made of a material that transmits light, and a plurality of fine protrusions that are made of a material that blocks light and are provided apart from each other on one surface in the thickness direction of the substrate. A mold installation step of installing the mold on the molding material such that the transfer pattern of the mold has a close contact with the uncured molding material installed in the uncured molding material installation step;
A molding material curing step of irradiating the molding material with light through a substrate of the mold and curing a part of the molding material after the mold is installed in the molding material in the mold installation step;
A mold separation step of separating the mold from the molding material after curing a part of the molding material in the molding material curing process;
An uncured molding material removing step of removing the uncured molding material after separating the mold from the molding material in the mold separation step;
A method for forming a molded article, comprising:

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