JP2021045905A - Method for manufacturing molding - Google Patents

Abstract

To suppress a trouble in which a part of a fine uneven structure of a mold is not transferred to a to-be-transferred material in a method for manufacturing a molding by an imprinting process.SOLUTION: A method for manufacturing a molding having a fine uneven structure includes a press step for pressing a to-be-transferred material to a transfer surface provided with the fine uneven structure of a mold having the transfer surface. In the method for manufacturing the molding, the pressing in the press step is carried out by sandwiching at least the to-be-transferred material and the mold by a press upper plate from a surface side opposite to the mold of the to-be-transferred material and by a press lower plate from a surface side opposite to the transfer surface of the mold using a pressing device provided with the press upper plate and the press lower plate. Alternately, in the press step, at least a buffer material is sandwiched between the mold and the press lower plate.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for producing a molded product. More specifically, the present invention relates to a method for producing a molded product by a so-called imprint process.

A method of manufacturing a molded product having a fine concavo-convex structure by a so-called "imprint process" is known.
The flow of the imprint process is as follows, for example.
(1) First, the resin material to be transferred is heated and softened.
(2) Next, the softened material to be transferred is pressed against a transfer surface having a fine structure provided on the surface of the mold and pressure-molded.
(3) The material to be transferred is cooled as it is (while the pressure is maintained).
(4) After the material to be transferred has cooled, the material to be transferred is released from the mold to obtain a resin molded body to which the fine structure of the transfer surface of the mold is transferred.

As an example of the prior art, Patent Document 1 states that, by an imprint process, a molding die is pressed against a semi-cured dry film in a heated state, and then cooled after pressing to obtain an uneven shape of the molding die. A method of forming an inverted and transferred Fresnel lens is disclosed.

As an example of another prior art, Patent Document 2 discloses a method of forming a membrane carrier having a concave microstructure used in a liquid sample inspection kit by an imprint process.

International Publication No. 2012/043573 International Publication No. 2016/098740

While studying the improvement of the imprint process, the present inventor presses the softened transfer material against the mold to produce a molded product having a fine uneven structure, which is a part of the fine uneven structure of the mold. Was found to be not transferred to the transfer material.

The present invention has been made in view of such circumstances. One of the objects of the present invention is to suppress a defect that a part of the fine concavo-convex structure of the mold is not transferred to the material to be transferred in the method of manufacturing the molded product by the imprint process.

As a result of diligent studies, the present inventors have completed the inventions provided below and solved the above problems.

According to the present invention
A method for producing a molded product having a fine concavo-convex structure, which comprises a pressing step of pressing a material to be transferred against the transfer surface of a mold having a transfer surface provided with a fine concavo-convex structure.
The pressing in the pressing step is performed by using a press device including a press upper plate and a press lower plate, and the die is transferred from the surface side of the material to be transferred opposite to the die by the press upper plate. From the surface side opposite to the surface, at least the transfer material and the mold are sandwiched by the press lower plate.
In the pressing step, a method for producing a molded product is provided in which at least a cushioning material is sandwiched between the mold and the press lower plate.

According to the present invention, in the method for manufacturing a molded product by an imprint process, it is possible to reduce the problem that a part of the fine concavo-convex structure of the mold is not transferred to the material to be transferred.

It is a schematic diagram for demonstrating the manufacturing method of a molded body. It is a schematic diagram for demonstrating the manufacturing method of a molded body. It is a schematic diagram for demonstrating the manufacturing method of a molded body. It is a figure for demonstrating "the mold".

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
In all drawings, similar components are designated by the same reference numerals, and description thereof will be omitted as appropriate.
In order to avoid complication, (i) when there are a plurality of the same components in the same drawing, only one of them is coded and all of them are not coded, or (ii) especially in the figure. In 2 and later, the same components as in FIG. 1 may not be re-signed.
All drawings are for illustration purposes only. The shape and dimensional ratio of each member in the drawing do not necessarily correspond to the actual article.

In the present specification, the notation "XY" in the description of the numerical range means X or more and Y or less unless otherwise specified. For example, "1 to 5% by mass" means "1% by mass or more and 5% by mass or less".
The notation "(meth) acrylic" herein represents a concept that includes both acrylic and methacrylic. The same applies to similar notations such as "(meth) acrylate".

<Manufacturing method of molded product>
1 (I. and II.), 2 and 3 are schematic views for explaining a method for producing a molded product of the present embodiment. More specifically, FIGS. 1, 2 and 3 can be said to be schematic cross-sectional views showing an "apparatus" for performing the method for manufacturing a molded product of the present embodiment, its operation, a procedure and the like. By the procedure as shown in FIGS. 1, 2 and 3 described below, it is possible to suppress a problem that a part of the fine concavo-convex structure of the mold is not transferred to the material to be transferred.

(Fig. 1: Preparation before pressing process)
I. of FIG. Is a diagram for explaining a pre-stage (preparation stage) of the pressing process described with reference to FIG.
I. of FIG. On the lower surface side of the press upper plate 31, a backing plate 33, a metal foil 34, a low friction member 35, and a transfer material 20 are installed in order from the side closer to the lower surface.
As a reminder, if at least the lower surface of the press upper plate 31, both sides of the backing plate 33, both sides of the metal foil 34, and at least the upper surface of the transfer material 20 are sufficiently flat, the I.C. As described above, the backing plate 33, the metal leaf 34, and the material to be transferred 20 can be prevented from "falling down" due to gravity (because air does not enter between the members). Of course, some or all of these may be physically fixed so as not to fall by some means.
I. of FIG. On the upper surface side of the press lower plate 32, a backing plate 38, a cushioning material 37, a rigid body plate 36, and a die 10 are installed in order from the side closer to the upper surface.

II. Of FIG. Is the I. It is a figure for demonstrating the pre-stage (preparation stage) of the pressing process described in FIG. 2, which is different from the above.
II. Of FIG. In FIG. 1, the metal foil 34, the low friction member 35, and the transfer material 20 are installed not on the lower surface side of the press upper plate 31 but on the upper surface side of the press lower plate 32. Different from. More specifically, II. In (i), a backing plate 38, a cushioning material 37, a rigid body plate 36, and a mold 10 are installed on the upper surface side of the press lower plate 32 in this order from the side closer to the upper surface, and (ii) further, the mold thereof. The transfer material 20, the low friction member 35, and the metal foil 34 are installed on the transfer surface 10a (provided with the fine concavo-convex structure) side of the 10 in order from the side closest to the transfer surface.

I. of FIG. And II. The press upper plate 31 and the press lower plate 32 can press the surface 20a of the material to be transferred 20 against the transfer surface 10a of the die 10.
Usually, at least one (preferably both) of the press upper plate 31 and the press lower plate 32 has a built-in heating means. The mold 10 and the material to be transferred 20 can be heated by the heating means. Then, the mold 10 and / or the transfer material 20 can be pressed while being heated.
I. of FIG. Or II. In the preparatory stage shown in 1, each member such as the transfer material 20 and the mold 10 may be heated. As a result, for example, the time required for the following pressing process can be shortened, leading to an improvement in industrial efficiency. When this heating is performed, the temperature of the material to be transferred 20 may be lower than the glass transition temperature or higher than the glass transition temperature. The latter is preferable in terms of improving the productivity (shortening the time) of the entire process.

(Fig. 2: Pressing process)
FIG. 2 shows the I. Or II of FIG. It is a figure for demonstrating the step (pressing step) of pressing the transfer material 20 against the transfer surface 10a of a mold 10 by changing the state of.
Pressing in the pressing step is performed by using a press device including a press upper plate 31 and a press lower plate 32, and from the surface side of the transfer material 20 opposite to the die 10, the press upper plate 31 is used to press the die 10. From the side opposite to the transfer surface 10a, a member such as the transfer material 20 or the die 10 is sandwiched by the press lower plate 32.

In the pressing step, heating is usually performed together with pressing. Specifically, the pressing step is performed while heating the member sandwiched between the press upper plate 31 and the press lower plate 32 by the heating means built in the press upper plate 31 and / or the press lower plate 32.
Specifically, the method of heating the transfer material 20 is (i) a method of heating the transfer material 20 by using the heating means built in the press upper plate 31, and (ii) being built in the press lower plate 32. A method of heating the die 10 using a heating means and transferring heat to the transfer material 20 when the transfer material 20 is pressed, (iii) a combination of these (i) and (ii), that is, with the press upper plate 31. A method of using "both" of the press lower plate 32 and the like can be mentioned. In the case of (iii), the temperature of heating by the press upper plate 31 and the temperature of heating by the press lower plate 32 may be the same or different.

In the pressing step, the material to be transferred is typically heated to 50 to 300 ° C., preferably 60 to 250 ° C., more preferably 80 to 200 ° C.
As another viewpoint, when the glass transition temperature of the transferred material 20 is Tg, the transferred material 20 is preferably Tg [° C.] or higher, more preferably Tg + 5 [° C.] or higher, and further preferably Tg + 10 [] in the pressing step. ℃] or higher. The upper limit of this is, for example, Tg + 100 [° C.] or less.
By the way, in each step, the "temperature at which the surface pressed against the transfer surface 10a of the material to be transferred 20 is heated" in a stable temperature state is usually regarded as the same as the temperature of the mold 10. it can. In particular, when the material to be transferred 20 is in the form of a film (that is, when the material to be transferred 20 is thin), the temperature of the material to be transferred 20 pressed against the transfer surface 10a quickly reaches the temperature of the mold 10. It is thought that.

The pressure in the pressing step is, for example, 0.5 MPa or more. This pressure is preferably 0.8 to 30 MPa, more preferably 1 to 20 MPa. When the pressure in the pressing step is 0.5 MPa or more, the material to be transferred 20 is sufficiently deformed, and a molded product can be appropriately manufactured. Further, it is considered that when the pressure in the pressing step is 50 MPa or less, damage to the mold 10 can be suppressed and the life of the mold 10 can be extended.
The time of the pressing process is not particularly limited. From the viewpoint of production efficiency and sufficient plastic deformation of the material to be transferred 20, it is, for example, about 0.5 to 10 minutes.

In the pressing step, at least a cushioning material 37 is sandwiched between the die 10 and the press lower plate 32. As a result, it is possible to suppress a problem that a part of the fine uneven structure of the mold 10 is not transferred to the transfer material 20. When the pressing step is performed without using the cushioning material 37, non-uniformity is likely to occur in the pressure, and transfer defects are likely to occur.

(Release process)
By releasing the transfer material 20 from the mold 10 after the pressing step (mold release step), a molded product having a fine concavo-convex structure can be obtained.
FIG. 3 is a diagram schematically showing a mold release process. In FIG. 3, the description of the components other than the transfer material 20 and the mold 10 is omitted.

The mold release step is usually performed after the pressing step is performed, the pressing is released, and the material to be transferred 20 is sufficiently cooled. The method for cooling the material to be transferred 20 is not particularly limited. For example, a method of leaving it in the atmosphere, a method of blowing wind, and the like can be mentioned.

As described above, a molded product having a fine concavo-convex structure can be manufactured by the procedure as shown in FIGS. 1, 2 and 3.

The series of flow of the manufacturing method of the molded product of this embodiment is as described above.
Hereinafter, a more specific description of the method for producing the molded product of the present embodiment will be added.

(Cushioning material 37)
As the cushioning material 37, any material can be used as long as it is a paper that can alleviate the pressure non-uniformity when it exists between the mold 10 and the press lower plate 32. The cushioning material 37 preferably has heat resistance that can withstand heating during the pressing step (substantially carbonized by heating during the pressing step, etc.).
A new cushioning material 37 may be used each time the pressing step is performed, or the cushioning material 37 may be used repeatedly as long as it has cushioning properties.

Specific examples of the cushioning material 37 include various types of paper used in a hot press when manufacturing a laminated board such as a printed wiring board. More specifically, in the paper industry, it can be appropriately selected and used from those distributed under names such as kraft paper, cushion paper, and linter paper. Here, the linter paper is a paper for a printed wiring board made of cotton pulp, and is often used as a cushioning material when the printed wiring board is pressed. Since linter paper is made from cotton pulp, it has good cushioning properties.
Further, as a cushion paper having particularly excellent heat resistance, a cushion paper containing polyborate as described in Japanese Patent No. 591806 can also be used.

Paper that can be used as the cushioning material 37 (kraft paper, cushion paper, linter paper, etc.) can be obtained from paper manufacturers such as Tokyo Special Paper Industry Co., Ltd. and Daio Paper Co., Ltd.

Examples of the cushioning material 37 include, in addition to the above-mentioned paper, a resin film, a sheet-shaped rubber, and the like. The material of the cushioning material 37 is not particularly limited as long as it can be appropriately deformed by the pressing pressure in the pressing step to disperse the pressure.

(Metal leaf 34)
By sandwiching the metal foil 34 between the transfer material 20 and the press upper plate 31 (in FIG. 1, between the low friction member 35 and the backing plate 33), the pressing after the pressing step is released and the press is pressed. When the plate 31 and the press lower plate 32 are separated from each other, it is possible to prevent the transfer material 20 and the low friction member 35 from sticking to the press upper plate 31 side together with the mold 10. Then, after the pressing step, the members of the metal foil 34 or less are likely to remain on the side of the press lower plate 32. Since the member remains on the side of the press lower plate 32, the peeling step can be efficiently performed (it is not necessary to "take" the member from the side of the press upper plate 31). Moreover, since the metal foil has good thermal conductivity, it does not interfere with the heating of the material to be transferred.
That is, by using the metal foil 34 under the backing plate 33, it is possible to improve the mass productivity when the molded product is industrially mass-produced.

The metal leaf 34 can be any metal leaf. From the viewpoint of cost and availability, the metal foil 34 is preferably an aluminum foil.
The thickness of the metal foil 34 is not particularly limited, but is, for example, 1 to 100 μm, preferably 5 to 50 μm.

In terms of the above-mentioned effect of improving mass productivity, the metal foil 34 may be a plate instead of a foil. That is, the metal foil 34 may be a metal plate or the like.

(Low friction member 35)
By installing the low friction member 35 on the upper surface (the surface opposite to the mold 10) of the material to be transferred 20, it is easy to suppress the occurrence of unintended wrinkles in the obtained molded product.
Presumably, when the material to be transferred 20 is heated in the pressing step, the material to be transferred 20 "expands", causing "deflection", "distortion", and the like. If the transferred material 20 having the "deflection" and "distortion" is pressed against the transfer surface 10a as it is, it is presumed that wrinkles are generated in the transfer material 20 due to the "deflection" and "distortion". .. However, if the low friction member 35 is in contact with the surface of the transfer material 20 on the side opposite to the mold 10, the "low friction" of the low friction member 35 causes the "deflection" of the transfer material 20. It is presumed that the "distortion" is well escaped and wrinkles are less likely to occur.

The low friction member 35 is preferably a resin film. When the low friction member 35 is a resin film, its thickness is preferably 1 to 1000 μm, more preferably 10 to 800 μm, still more preferably 20 to 500 μm.

The low friction member 35 preferably contains one or more resins selected from the group consisting of polyimides, polyesters and polyetheretherketones. By adopting one or more of these resins as the material of the low friction member 35, it is easy to reduce the friction coefficient of the low friction member 35. Further, since these resins have relatively high heat resistance, it is easy to avoid a situation in which the low friction member 35 is deformed in the pressing process. Moreover, since it has high heat resistance, it is also preferable in terms of repeated use.
By the way, in order to surely avoid the deformation of the low friction member 35, the temperature during the pressing process is adjusted so that the glass transition temperature of the material to be transferred 20 <the temperature during the pressing process <the glass transition temperature of the low friction member 35. It is preferable to select a member having an appropriate glass transition temperature for each member.

The static friction coefficient of the low friction member 35 (to be exact, the static friction coefficient of the surface of the low friction member 35 in contact with the material to be transferred 20) is 10 or less, preferably 5 or less, more preferably 3 or less, still more preferably 1 or less. Is.
There is no particular lower limit to the coefficient of static friction, and basically, the smaller the coefficient of static friction, the less likely it is that wrinkles will occur in the molded product. However, from a realistic point of view, the coefficient of static friction is, for example, 0.01 or more, specifically 0.1 or more.

The coefficient of static friction is such that the material to be transferred 20 (for example, a resin film of polycycloolefin) and the low friction member 35 are superposed and rubbed at a speed of 100 mm / min under a load of 200 g according to JIS K 7125. It can be determined by conducting a test. The measurement environment at this time is preferably set to 23 ° C. and 50% RH.

As the low friction member 35, a member having a static friction coefficient of 10 or less can be selected and used from commercially available products (films) available from synthetic resin makers, film makers and the like.

(Transfer material 20)
The material to be transferred 20 has a property of being softened by heating, and can be made of any material, shape, or the like as long as it can form a fine concavo-convex structure when pressed against the transfer surface 10a of the mold 10 in the pressing step. There can be.

The transfer material 20 is preferably a resin film. Since the material to be transferred 20 is in the form of a film, it is easy to apply pressure uniformly to the material to be transferred 20, and it is easy to manufacture a molded product having good dimensional accuracy.

The transfer material 20 usually contains a thermoplastic resin and / or a thermosetting resin. Considering the ease of mold release in the mold release step, the ease of subsequent processing of the manufactured molded product, and the like, the material to be transferred 20 preferably contains a thermoplastic resin.

The transfer material 20 includes, for example, methyl poly (meth) acrylate, polycarbonate, polycycloolefin, polyethylene, polystyrene, polypropylene, acrylonitrile / styrene copolymer, acrylonitrile / butadiene / styrene copolymer, polynorbornene, polyethylene terephthalate and the like. Can be included. These are usually classified as thermoplastic resins.
From another viewpoint, the material to be transferred 20 preferably contains an amorphous resin. Since the amorphous material has a wide molding temperature range, it has good moldability and is effective in improving dimensional stability. Examples of the amorphous resin include methyl poly (meth) acrylate, polycarbonate, polycycloolefin, polystyrene, (meth) acrylonitrile / styrene copolymer, and (meth) acrylonitrile / butadiene / styrene copolymer.
The transfer material 20 may contain only one kind of resin, or may contain two or more kinds of resins.

The glass transition temperature Tg of the material to be transferred 20 is typically 50 to 300 ° C, preferably 60 to 250 ° C, and more preferably 70 to 200 ° C.

As the glass transition temperature, for example, the temperature at the inflection point at which the storage elastic modulus begins to decrease when the material to be transferred 20 is dynamically measured for viscoelasticity can be adopted. The measurement mode of the dynamic viscoelasticity measurement can be a shear mode, the frequency can be 1 Hz, and the heating rate can be 5 ° C./min.

The transfer material 20 preferably contains one or more resins selected from the group consisting of polycycloolefin, polycarbonate, polymethylmethacrylate and polystyrene. In particular, polycycloolefin is preferable from the viewpoint of good releasability. In addition, polycycloolefin is preferable in terms of optical properties when the molded product is applied to a molded product application (biochip or the like) described later.

When the transfer material 20 is a resin film, the thickness thereof is preferably 0.01 to 10 mm, more preferably 0.02 to 5 mm, still more preferably 0.04 to 2 mm.
By setting the thickness of the transfer material 20 to 0.01 mm or more, it is possible to further suppress the occurrence of wrinkles on the transfer material 20. Further, by reducing the thickness of the material to be transferred to 10 mm or less, the cooling property of the material to be transferred 20 is enhanced, and the production efficiency / production time can be shortened.

As the transfer material 20, a commercially available product available from a synthetic resin maker, a film maker, or the like can be used.

(Mold 10)
FIG. 4 is a schematic view for explaining the mold 10 in FIGS. 1, 2 and 3. Specifically, FIG. 4A. Is a top view showing the transfer surface 10a of the mold 10. In addition, FIG. 4B. Is an XX vertical cross-sectional view of the mold 10.
The transfer surface 10a of the mold 10 usually has a plurality of convex portions. The shape of each convex portion can be, for example, a columnar shape, a cone shape, a hemispherical shape, a shape in which corners of these shapes are chamfered, a shape in which each shape is connected, a shape in which each shape is combined, or the like. The "columnar" here includes a columnar column, a square columnar shape, and the like.
Further, the transfer surface 10a may have a striped uneven microstructure.

The mold 10 is preferably a Ni electroformed mold. In other words, it is preferable that at least the transfer surface 10a of the mold 10 is Ni electroformed. The Ni electroformed mold is preferable in terms of wear resistance and the like.

The pitch (p in FIG. 4A.) Of the convex portion of the fine concavo-convex structure provided on the transfer surface 10a is, for example, 0.02 to 6000 μm, specifically 0.04 to 4000 μm, and more specifically 0.06 to 0.06 to It is 2000 μm.
When the convex portion of the fine concavo-convex structure provided on the transfer surface 10a is a cylinder, the diameter of the cylinder (d in FIG. 4A.) Is, for example, 0.1 to 3000 μm, specifically 0.2 to 2000 μm. Specifically, it is 0.3 to 1000 μm.
The height of the convex portion of the fine concavo-convex structure provided on the transfer surface 10a (h in FIG. 4B) is, for example, 0.01 to 3000 μm, specifically 0.02 to 2000 μm, and more specifically 0.03. It is ~ 1000 μm.

The mold 10 can be manufactured by a known manufacturing method.

(Rigid body plate 36)
The rigid body plate 36 can be mainly used for suppressing deformation or reinforcing the mold 10.
The term "rigid body" here does not mean only a strict rigid body (an object that does not deform under the action of force) in physics, but also includes the meaning that it is sufficiently less deformable than the mold 10. .. For example, the material of the rigid body plate 36 is preferably made of a material harder than the material of the mold 10. Further, even if the material of the rigid body plate 36 itself is softer than the material of the mold 10, the thickness of the rigid body plate 36 is sufficiently thicker than that of the mold 10, so that the function of suppressing the deformation of the mold 10 and reinforcing the mold 10 is fulfilled. You may be.

The rigid plate 36 is preferably made of metal. That is, the rigid plate 36 is preferably a metal plate. From the viewpoint of hardness and durability, a steel plate or a stainless steel plate is preferable, and a stainless steel plate is more preferable.
The thickness of the rigid plate 36 is not particularly limited, but is, for example, 0.1 to 10 mm, preferably 0.3 to 5 mm.

(Reliable plate 33 / Reliable plate 38)
The backing plate 33 is usually used to suppress damage to the press upper plate 31. Further, the backing plate 38 is usually used to suppress damage to the press lower plate 32. That is, the backing plate 33 and the backing plate 38 are not "essential" for the production of the molded product. However, it is preferable that the backing plate 33 and the backing plate 38 are used for the purpose of suppressing damage to the press upper plate 31 and the press lower plate 32 and extending the life of the apparatus. Further, by performing the pressing step through the backing plate 33 and / or the backing plate 38, it is easy to make the pressing force uniform even when the surfaces of the press upper plate 31 and the press lower plate 32 have irregularities. Can also be said.

The materials of the backing plate 33 and the backing plate 38 are not particularly limited, but a silicon wafer is preferable in terms of market availability, good flatness, and the like.

(Use of manufactured molded product)
The use of the molded product having the fine concavo-convex structure obtained as described above is not particularly limited.
Examples of applications include biochips and the like. That is, a biochip can be obtained by fixing a recognition substance such as a specific antibody to the concave portion of the molded product (corresponding to the convex portion of the transfer surface 10a).
For specific aspects of the biochip, for example, JP-A-2015-49161 and JP-A-2015-49162 can be referred to.

Although the embodiments of the present invention have been described above, these are examples of the present invention, and various configurations other than the above can be adopted. Further, the present invention is not limited to the above-described embodiment, and modifications, improvements, and the like within the range in which the object of the present invention can be achieved are included in the present invention.

Embodiments of the present invention will be described in detail based on Examples and Comparative Examples. As a reminder, the invention is not limited to examples.

<Preparation>
The following members were prepared.

(Cushioning material)
Cushion paper from Tokyo Special Paper Industry Co., Ltd., KS-190, weighing 190 g / m ²

(Mold)
A Ni electroformed mold having a columnar convex portion on the transfer surface as shown in FIG. 4 was prepared.
The diameter (d in FIG. 4) of the columnar convex portion was 10 μm, the height (h in FIG. 4) was 10 μm, and the pitch (p in FIG. 4) was 20 μm.

(Transfer material)
The following was used.
-COP: Polycycloolefin resin film (Zeonoa film ZF-14 manufactured by Zeon Corporation, thickness: 0.19 mm, glass transition temperature: 136 ° C.)

The glass transition temperature Tg of the material to be transferred was determined from the results of dynamic viscoelasticity measurement under the following conditions. For Tg, the temperature of the inflection point at which the storage elastic modulus began to decrease was used.
-Measuring device: ARES-2KFRTN1-FCO-HR manufactured by TA Instruments Co., Ltd.
-Sample size: Parallel plate φ25 mm, gap 2 mm
-Measurement temperature range: 100 to 180 ° C
・ Temperature rise rate: 5 ° C / min
・ Frequency: 1Hz
・ Mode: Shear mode

(Metal leaf)
Commercially available aluminum foil, thickness 12 μm

(Low friction member)
125 μm thick PI (polyimide) film, static friction coefficient 0.35
As for the coefficient of static friction, as described above, the transfer material (COP) and the low friction member are superposed, and a friction test is carried out at a speed of 100 mm / min under a load of 200 g according to JIS K 7125. Asked by doing. The measurement environment was set at 23 ° C. and 50% RH.
The measurement was carried out three times, and the average of the obtained three values was adopted as the coefficient of static friction.

(Rigid body plate)
1mm thick stainless steel plate

(Reliable plate (press upper plate side and press lower plate side))
Commercially available 6-inch silicon wafer

<Example 1: Manufacture of molded product>
The procedure was as follows.
(1) II. Of FIG. As shown in, members such as a transfer material, a mold, and a cushioning material were arranged between the press upper plate and the press lower plate (with a built-in heating means).
(2) The mold or the like was heated to 155 ° C. by using the heating means of the press lower plate (the material to be transferred was heated to the glass transition temperature Tg or more by this heating).
(3) While maintaining the above temperature, the material to be transferred COP was pressed against the transfer surface of the die by the press upper plate and the press lower plate, and pressed at a pressure of 4 MPa for 2 minutes.
(4) After that, the temperature of the mold and the material to be transferred COP was cooled to 135 ° C. over about 3 minutes while pressing at the same pressure.
(5) Raise the upper plate of the press and apply cold air from above to the one on which the mold and the material to be transferred are integrated on the lower plate of the press, and bring the material to be transferred sufficiently (at least to a temperature of Tg or less). ) Cooled.
(6) The transfer material COP was released from the mold to obtain a molded product having a fine concavo-convex structure.

<Comparative Example 1: Manufacture of molded product>
A molded product was obtained by the same procedure as in Example 1 except that the cushioning material was not arranged.

<Confirmation of transferability of the fine uneven structure of the mold>
In the molded product obtained in Example 1, unevenness substantially faithful to the unevenness of the mold was formed in the entire portion of the transfer material COP on which the mold was pressed.
On the other hand, in the molded product obtained in Comparative Example 1, there was a part where the unevenness of the mold was not satisfactorily transferred. It is highly probable that the lack of cushioning material caused non-uniformity in the pressure, leading to transfer defects.

<Visual evaluation of wrinkles>
The molded product obtained in Example 1 was carefully visually observed. No wrinkles were found.

10 Die 10a Transfer surface 20 Transfer material 20a Surface 31 Press upper plate 32 Press lower plate 33 Back plate 34 Metal leaf 35 Low friction member 36 Rigid body plate 37 Cushioning material 38 Back plate

Claims (17)

A method for producing a molded product having a fine concavo-convex structure, which comprises a pressing step of pressing a material to be transferred against the transfer surface of a mold having a transfer surface provided with a fine concavo-convex structure.
The pressing in the pressing step is performed by using a press device including a press upper plate and a press lower plate, and the die is transferred from the surface side of the material to be transferred opposite to the die by the press upper plate. From the surface side opposite to the surface, at least the transfer material and the mold are sandwiched by the press lower plate.
A method for producing a molded product, in which at least a cushioning material is sandwiched between the mold and the press lower plate in the pressing step. The method for producing a molded product according to claim 1.
A method for producing a molded product, wherein the material to be transferred is a resin film. The method for producing a molded product according to claim 1 or 2.
A method for producing a molded product, wherein the transferred material contains a thermoplastic resin. The method for producing a molded product according to any one of claims 1 to 3.
A method for producing a molded product, wherein the transferred material contains one or more resins selected from the group consisting of polycycloolefin, polycarbonate, polymethylmethacrylate and polystyrene. The method for producing a molded product according to any one of claims 1 to 4.
A method for producing a molded product, in which a metal foil or a metal plate is sandwiched between the transfer material and the press upper plate in the pressing step. The method for producing a molded product according to claim 5.
A method for manufacturing a molded product, wherein the metal foil or metal plate is an aluminum foil. The method for producing a molded product according to any one of claims 1 to 6.
A method for producing a molded product, wherein in the pressing step, a low friction member having a static friction coefficient of 10 or less is in contact with a surface of the material to be transferred opposite to the mold. The method for producing a molded product according to claim 7.
A method for manufacturing a molded product, wherein the low friction member is a resin film. The method for producing a molded product according to claim 7 or 8.
A method for producing a molded product, wherein the low friction member contains one or more resins selected from the group consisting of polyimide, polyester and polyetheretherketone. The method for producing a molded product according to any one of claims 1 to 9.
A method for manufacturing a molded body in which a rigid plate is sandwiched between the mold and the cushioning material in the pressing step. The method for producing a molded product according to claim 10.
A method for manufacturing a molded body, wherein the rigid body plate is made of metal. The method for producing a molded product according to any one of claims 1 to 11.
In the pressing step, a method for manufacturing a molded product, in which a backing plate is in contact with the lower surface of the press upper plate. The method for producing a molded product according to any one of claims 1 to 12.
In the pressing step, a method for manufacturing a molded product, in which a backing plate is in contact with the upper surface of the press lower plate. The method for producing a molded product according to any one of claims 1 to 3.
A method for manufacturing a molded body, wherein the mold is a Ni electroformed mold. The method for producing a molded product according to any one of claims 1 to 8.
A method for producing a molded product, wherein the height of the convex portion of the fine concavo-convex structure provided on the transfer surface is 0.01 to 3000 μm. The method for producing a molded product according to any one of claims 1 to 15.
A method for producing a molded product, wherein in the pressing step, the material to be transferred is heated to 50 to 300 ° C. The method for producing a molded product according to any one of claims 1 to 16.
A method for producing a molded product, which comprises a mold release step of releasing the transfer material from the mold after the pressing step.

Images