JP6531052B2 - Method of manufacturing reverse mold, method of manufacturing functional sheet, and peeling apparatus - Google Patents

Description

  The present invention relates to a method of manufacturing a reverse mold, a method of manufacturing a functional sheet, and a peeling apparatus, and more particularly to a technology of peeling a resin film and a convex original plate when manufacturing a reverse mold.

  In recent years, functional sheets in which a plurality of fine needle-like convex portions (also referred to as microneedles or microneedles) having a high aspect ratio structure are arranged in an array on the surface have attracted attention. The functional sheet is, for example, a sheet containing a drug in a plurality of fine needle-like convex portions pressed against the skin and inserting the needle-like convex portion into the skin, the drug of the needle-like convex portion into the skin There is a transdermal absorption sheet to deliver.

  In order to manufacture a functional sheet, it manufactures using the inversion mold in which the fine needle-like recessed part which is the reverse shape of a fine needle-like convex part is arrange | positioned at array shape. In order to manufacture this inversion mold, first, a convex original plate in which needle-like convex portions are arranged in an array is manufactured. Then, a resin for molding is added to the produced convex original plate and solidified to transfer the needle-like convex part, and the resin film after transfer is peeled off from the convex original plate to invert the fine needle-like concave part. It is common to manufacture molds. As a resin for producing a reverse mold, a thermoplastic resin, a thermosetting resin, and a photocurable resin are used, and in particular, a silicone resin having excellent releasability is often used.

  However, in the peeling step of peeling the resin film and the convex original plate, the resin film may be torn, the transferred needle-like concave portion may be broken, or the needle-like convex portion of the convex original plate may be broken. Defects are likely to occur.

  Moreover, since the resin inversion mold is damaged by repeated production of the functional sheet, it is necessary to manufacture a plurality of inversion molds from one convex original plate. However, in order to prevent the occurrence of peeling failure, the resin film has to be peeled slowly from the convex master plate over time, and the productivity at the time of manufacturing a plurality of reversal molds is lowered. That is, the reduction in productivity in the peeling step is the bottleneck in improving the productivity of the reverse mold.

  As a measure against peeling failure, a convex original plate is coated with a release agent in advance. Moreover, there exists patent document 1, for example as a countermeasure which prevents peeling defect by devising the peeling method at the time of peeling a resin film from a type | mold.

  Patent Document 1 includes a first peeling step of starting peeling by bending a substrate supporting a resin film into a curved shape, and a second peeling step of peeling the remaining by gradually returning the bending. We have proposed a peeling method.

  Also, although there is no method of peeling the resin film from which the fine needle-like convex portions have been transferred from the convex original plate, there is a method of peeling the fuel cell separator from the molding die without peeling failure using the suction pad. Patent Document 2 proposes.

  In Patent Document 2, a short free-length pad support leg provided with a suction pad and a long free-length pad support leg provided with a suction pad are supported by a moving frame that moves up and down, and the width of the separator is set by each suction pad. It is described that peeling is gradually advanced from one end to the other end of the separator using a mold release device that adsorbs one direction end and the other end. That is, it is supposed that by gradually advancing peeling from one end side to the other end side of the object to be peeled, it is possible to peel from the molding die without damaging the separator.

Unexamined-Japanese-Patent No. 2010-234669 Unexamined-Japanese-Patent No. 2010-234749

  However, even with any of the peeling methods of Patent Document 1 and Patent Document 2, it is impossible to peel the resin film having the fine needle-like concave portion to which the fine needle-like convex portion is transferred from the convex master without the above-mentioned peeling failure. . Further, in the case of Patent Document 1, there is a concern that the substrate may be broken by bending the substrate in a curved shape.

  Furthermore, in Patent Documents 1 and 2, all measures are taken as to how to speed up peeling in order to prevent a decrease in productivity when manufacturing a plurality of resin inverted molds from one mold master plate. Not listed. As in Patent Document 2, although peeling defects may be prevented by gradually advancing peeling from one end side to the other end side of the object to be peeled, productivity improvement in manufacturing a reverse mold is not achieved.

  That is, although various methods have been proposed for producing a reverse mold having fine needle-like concave portions by transfer from a convex original plate having a plurality of fine needle-like convex portions, high quality transferred accurately without peeling failure. The fact is that sufficient study has not been made on a method of manufacturing a reverse mold with high productivity.

  The present invention has been made in view of the above circumstances, and a resin film having fine needle-like concave portions to which fine needle-like convex portions are transferred can be peeled rapidly from the convex master without peeling defect, and therefore high. It is an object of the present invention to provide a method of manufacturing a reverse mold capable of manufacturing a high quality reverse mold with high productivity, a method of manufacturing a functional sheet, and a peeling apparatus.

  In order to achieve the object, the method of manufacturing a reverse mold of the present invention includes the steps of producing a convex master having a plurality of fine needle-like convex portions arranged in an array, and applying a resin for molding to the convex master. And solidifying to form a resin film on which needle-like convex portions are transferred, and peeling the resin film from the convex master plate, thereby producing a reverse mold having needle-like concave portions where needle-like convex portions are reversed. In the peeling method, the peeling step of peeling the resin film from the convex master plate is performed by providing an adsorption plate on the opposite surface of the resin mold on the convex master plate, and adsorbing and holding the peripheral portion or opposite end portions of the resin film A separation step of relatively separating the film from the convex original plate, and an absorption region expansion step of expanding the adsorption region of the resin film to the suction plate stepwise or continuously from the peripheral edge or opposite both ends to the central region. Including.

  According to the method of manufacturing a reverse mold of the present invention, in the separating step, the resin film is separated relatively from the convex original plate by suction holding the peripheral portion or the opposite end portions of the resin film on the suction plate. As a result, the peripheral portion or the opposite end portions of the resin film are first peeled off.

  Then, in the adsorption area expansion step, the adsorption area of the resin film with respect to the adsorption plate is expanded stepwise or continuously from the peripheral portion or both opposing end portions to the central portion. As a result, the resin film is exfoliated stepwise or continuously from the peripheral edge portion or opposing both end portions to the central portion, and the entire surface of the resin film is finally exfoliated from the convex original plate.

  As described above, in the present invention, the resin film's adsorption region with respect to the suction plate is expanded stepwise or continuously from the peripheral portion or opposite end portions to the center portion to peel the resin film from the convex master.

  Thus, the final peeling can be realized in a state where the separation distance between the suction plate and the convex original plate is short, so that the resin film having the fine needle-like concave portions to which the fine needle convex portions are transferred is peeled off from the convex original plate Can be peeled off quickly. In addition, since the reverse mold can be manufactured rapidly and without peeling defects, the yield and the production efficiency are improved, which also contributes to the reduction of the manufacturing cost.

  As an aspect of the present invention, in the case where the adsorption area expansion process is performed while maintaining the resin film and the convex master relatively separated in the separation process, the separation process and the adsorption area expansion process are performed in parallel. In the case where the separation step and the adsorption area enlargement step are alternately performed a plurality of times, any of the three methods may be used.

  As an aspect of the present invention, it is preferable that the resin film after solidifying the resin solution has elasticity. Here, having elasticity means that Young's modulus is small.

  In the process of expanding the adsorption region of the resin film to the adsorption plate stepwise or continuously from the peripheral edge or opposite both ends to the central portion, the resin film having elasticity is an air gap between the adsorption plate and the convex master. The resin film of a part will be in the extended state, and when the extension is going to shrink, it peels from the convex original plate. Thereby, since an excessive peeling force is not applied to the peeling portion between the resin film and the convex master, peeling failure can be further prevented.

  As the resin film having elasticity, it is preferable to use a thermosetting elastomer resin such as a silicone resin or the like, such as silicone resin, which has elasticity after the resin solution is solidified and which is excellent in releasability. Can.

  As an aspect of the present invention, it is preferable to have a non-transfer region at the peripheral portion or opposite end portions of the resin film. Thereby, the peeling defect in the vicinity of the peeling start can be prevented reliably.

In order to achieve the object of the method of producing a functional sheet of the present invention, a polymer solution applying step of applying a polymer solution for functional sheet to the inverted mold produced by any of the above-mentioned production methods, and polymer solution applying The method includes a polymer solution solidifying step of solidifying the polymer solution applied in the step to form a polymer film, and a peeling step of peeling the polymer film solidified in the polymer solution solidifying step.

  According to the method of producing a functional sheet of the present invention, since the low-cost and high-quality inversion mold produced by the present invention is used, a high-quality functional sheet can be produced at low cost.

  In order to achieve the object of the peeling apparatus of the present invention, a convex original plate in which a plurality of fine needle-like convex portions are arranged in an array, and a resin for molding is applied to the convex original plate to solidify it. In a peeling device for peeling the resin film to which the convex portion is transferred, the resin film is provided on the opposite surface of the convex original plate, and the adsorption force of the suction surface is expanded from the peripheral portion of the resin film or both ends to the central portion It includes a suction plate divided as possible into a plurality of suction areas, a separation means for relatively separating the suction plate and the convex original plate, and a control means for controlling the suction plate and the separation means.

  In order to achieve the object of the peeling apparatus of the present invention, a convex original plate in which a plurality of fine needle-like convex portions are arranged in an array, and a resin for molding is applied to the convex original plate to solidify it. In a peeling apparatus for peeling a resin film to which a convex portion is transferred, a suction plate having a suction surface on the reverse side of a convex original plate of a resin film, and a suction surface to contact the suction surface, leaving both opposing ends of the suction surface A thin plate configured such that the suction area of the suction surface is continuously expanded in the central portion by closing the suction surface and sliding the contact surface while keeping the suction surface in contact to reduce the blocked portion of the suction surface. And a separation means for relatively separating the suction plate and the convex original plate, and a control means for controlling the suction plate, the thin plate and the separation means.

  The peeling apparatus of the present invention can rapidly peel the resin film having the fine needle-like concave part to which the fine needle-like convex part is transferred from the convex master without peeling defect.

  According to the method of manufacturing a reverse mold of the present invention, a resin film having fine needle-like concave portions to which fine needle-like convex portions are transferred can be rapidly peeled from a convex master without peeling defects, so high quality reverse mold It can be manufactured at low cost with good productivity. In addition, by producing a functional sheet using the reverse mold produced by the method of producing a reverse mold of the present invention, a high-quality functional sheet can be produced at low cost.

  Moreover, the peeling apparatus of this invention can peel the resin film which has the fine needle-like recessed part to which the fine needle-like convex part was transferred from a convex original plate rapidly and without peeling defect. Therefore, it is suitable as a peeling apparatus of the peeling process in the manufacturing method of a reversal mold.

Diagram of convex original plate production in functional sheet production of the present invention Diagram of resin application process for mold in functional sheet production Diagram of resin solidification process for mold in functional sheet production Figure of inverted mold obtained by peeling resin film and convex original plate in functional sheet production Diagram of application process of polymer solution for functional sheet in functional sheet production Diagram of solidifying process of polymer solution for functional sheet in functional sheet production Figure of functional sheet obtained by peeling resin sheet and reverse mold in functional sheet production The whole block diagram of the exfoliation device of one embodiment of the present invention The perspective view explaining one mode of the adsorption board in exfoliation device Transverse view of the suction plate of FIG. 9 The perspective view explaining the other aspect of the adsorption board in exfoliation device The cross-sectional view of the suction plate of FIG. A plan view showing an example of a resin film adsorbed to an adsorption plate First step diagram of peeling process of peeling resin film from convex original plate Second step diagram of peeling process Third step diagram of peeling process Fourth step diagram of peeling process Fifth step diagram of peeling process Sixth step diagram of peeling process A conceptual diagram using a triangular thin plate in still another aspect of a suction plate in a peeling apparatus Action diagram of thin plate in the suction plate of Fig. 20 The figure of the case of using two triangular thin plates in the modification of the suction plate using thin plates

  BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of the method for producing a reverse mold, the method for producing a functional sheet, and the peeling apparatus according to the present invention will be described below with reference to the attached drawings.

  The invention is illustrated by the following preferred embodiments. Changes can be made in a number of ways without departing from the scope of the present invention, and other embodiments than the present embodiment can be used. Therefore, all the modifications within the scope of the present invention are included in the claims.

  Here, in the drawings, portions indicated by the same symbols are similar elements having similar functions. Further, in the present specification, when a numerical range is expressed using “to”, numerical values of upper limit and lower limit indicated by “to” are also included in the numerical range.

[Method of producing functional sheet]
1 to 7 are views for explaining the steps of the method for producing a functional sheet according to one embodiment of the present invention, and FIGS. 1 to 4 are steps for producing a reverse mold, and FIGS. It is a manufacturing process of a sheet (for example, a percutaneous absorption sheet).

  As shown in FIG. 1, the convex original plate 10 for producing the reversal mold 20 (see FIG. 4) for producing the functional sheet first is produced (step of producing the convex original plate).

  As means for producing the convex original plate 10, there are two types, ie, a convex original plate making means using an etching method and a convex original plate forming means using a cutting method. In the first etching method, after a photoresist is coated on a Si substrate by a coating unit, the photoresist is exposed by an exposure unit and developed by a developing unit. Then, etching such as RIE (Reactive Ion Etching) is performed by the etching means to form the same structure as the microneedles 32 (needles) of the functional sheet 30 (see FIG. 7) on the surface of the convex original plate 10. A plurality of fine needle-like convex portions 12 having a shape are manufactured in an array. When etching such as RIE is performed to form the needle-like convex portions 12 on the surface of the convex original plate 10, the needle-like convex portions 12 are etched by performing etching from an oblique direction while rotating the Si substrate. It is possible to form

  The second cutting method is an array of a plurality of fine needle-like convex portions 12 on the surface of the convex original plate 10 by processing using a cutting tool such as a diamond bite on a metal substrate of stainless steel, aluminum alloy, Ni or the like. Method to make it

  The cross-sectional shape of the fine needle-like convex portion 12 formed on the convex original plate 10 is not particularly limited, but for example, a needle having a shape such as a circle, an ellipse, and a polygon represented by triangle, square, pentagon, etc. It can be used.

  Moreover, as a size of the fine needle-like convex portion 12, for example, one having a diameter (diameter of a needle) of about 50 μm to 300 μm and a height of about 300 to 2000 μm is preferable.

  Next, as shown in FIG. 2, a spacer 14 is provided around the manufactured convex original plate 10, and a resin 16 for molding for producing a reverse mold in the spacer 14 (a resin before solidification or curing) ), And immersing the needle-like convex portion 12 of the convex original plate 10 (application step of resin solution for mold).

  As resin used for resin 16 for molds, although thermoplastic resin, thermosetting resin, photocurable resin etc. can be used, it is preferable to use the solution containing resin excellent in releasability. For example, a silicone resin obtained by adding a curing agent to PDMS (polydimethylsiloxane: SYLGARD 184 manufactured by Toray Dow Corning Co., Ltd.), which is a silicone resin, can be suitably used.

  As a means for applying the resin 16 for molding, any device capable of pouring the resin 16 for molding into a thin film in the spacer 14 may be used. For example, a slot die (not shown) having a slit-like discharge port Can be used suitably.

  Next, as shown in FIG. 3, the resin 16 for molding is solidified (hardened) to form the resin film 18 (solidification process of the resin solution for mold).

  As a means for solidifying (curing) the resin 16 for molding, when the resin 16 is a thermosetting resin, it is heated by a heating device (not shown), and in the case of a photocurable resin, light irradiation (ultraviolet rays etc. ) Can be solidified (cured) by light irradiation by an apparatus (not shown). Furthermore, when the resin 16 is a thermoplastic resin, it can be solidified by cooling or evaporating the solvent.

  Next, the resin film 18 (the resin film after solidifying or curing the resin 16) in FIG. 3 is peeled off from the convex original plate 10 (peeling step), as shown in FIG. A reverse mold 20 having a plurality of fine needle-like concave parts 22 formed by reversing the needle-like convex parts 12 is manufactured. Although the resin film 18 and the reverse mold 20 are substantially the same, the resin film 18 is referred to as the resin film 18 before being peeled off from the convex original plate 10 and to the reverse mold 20 after being peeled.

  The depth of the needle-like recess 22 of the reverse mold 20 to be manufactured can be adjusted by changing the immersion depth for immersing the needle-like convex portion 12 of the convex original plate 10 in the resin 16 in the step of solidifying the resin 16 for mold It is. The depth of the needle-like recess 22 of the reverse mold 20 (corresponding to the height of the microneedles 32 of the functional sheet 30) makes the microneedles 32 sufficiently large when the functional sheet 30 is manufactured, and It is preferable that it is 300 micrometers or more from a viewpoint of administering a functional component efficiently. On the other hand, the depth of the needle-like recess 22 is preferably 2000 μm or less from the viewpoint of sufficiently securing the strength of the microneedle 32.

  Therefore, when the height of the needle-like convex portion 12 of the convex original plate 10 matches the depth of the needle-like concave portion 22 of the reverse mold 20, the entire convex original plate 10 is immersed in the resin 16 for molding The spacer 14 may be provided on the

  Then, in the peeling step described above, the resin film 18 is torn during peeling, the needle-like concave portion 22 transferred to the resin film 18 is broken, and further, the needle-like convex portion 12 of the convex original plate 10 is broken. And other peeling defects are likely to occur. In addition, there is a problem that if the resin film 18 is peeled slowly from the convex master 10 in a long time in order to prevent peeling failure, the productivity for manufacturing the plurality of reverse molds 20 is reduced.

  The solution to these problems will be described in detail in the peeling apparatus and the method of manufacturing an inversion mold according to an embodiment of the present invention described later.

  Next, the functional film production process is performed as follows using the reverse mold produced in the above-described reverse mold production process.

  That is, as shown in FIG. 5, the reverse mold 20 obtained in the peeling step is disposed so that the needle-like concave portion 22 faces upward, the spacer 26 is provided around the reverse mold 20, and the functional sheet is provided in the spacer 26. Polymer solution 24 (application process of polymer solution for functional sheet).

  A polymer solution obtained by dissolving a high biosafety powder polymer such as gelatin, agarose, pectin, duran gum, carrageenan, xanthan gum, alginic acid and starch as a polymer solution 24 for functional sheet in a solvent such as warm water Can be used. The powdery polymer is preferably prepared at a concentration of 10 to 20% by mass, although it varies depending on the material. In addition, various liquids which have volatility can be used as a solvent, and you may use alcohol etc. besides warm water. An appropriate amount of functional component such as a drug is added to the polymer solution 24 for functional sheet.

  As a method of applying the polymer solution 24 for functional sheet to the inversion mold 20, methods such as coating using a spin coater, dropping using a dispenser, and the like can be mentioned.

  Next, as shown in FIG. 6, the polymer solution 24 for the functional sheet is solidified (cured) to form the polymer film 28 (solidification process of the polymer solution for the functional sheet). As a method of solidifying the polymer solution 24 for a functional sheet, there is a method of drying and solidifying the polymer solution 24 by blowing warm air or a method of gelling the polymer solution 24 by blowing cold air of low humidity.

  Finally, in FIG. 7, the polymer film 28 is peeled off from the reverse mold 20 (a peeling step of the resin sheet) to obtain a functional sheet 30 having a plurality of microneedles 32 as shown in FIG.

  By the steps shown in FIGS. 1 to 7 described above, the functional sheet 30 having the microneedles 32 (needles 32) with a high aspect ratio structure can be manufactured.

  Next, the peeling apparatus 50 of the present invention suitable as a peeling apparatus in the peeling step in the method of manufacturing a reverse mold will be described.

[Peeling device]
FIG. 8 is a partial cross-sectional view for explaining the entire configuration of the peeling device 50. As shown in FIG.

  As shown in FIG. 8, the peeling device 50 mainly includes a suction plate 34 provided on the opposite surface of the convex original plate 10 of the resin film 18 to which the needle-like convex portions 12 of the convex original plate 10 have been transferred. It is comprised by the separation | isolation means 36 which spaces apart 34 and the convex original 10 relatively, the control means 35, and the fixed disc 39 which fixes the convex original 10. As shown in FIG.

  The suction force of the suction surface 38 for holding the resin film 18 is divided into a plurality of suction areas so that the suction force of the suction surface 34 can be expanded from the peripheral portion or opposite end portions of the resin film 18 to the central portion. It is preferable that the number of divisions of the adsorption area is large, because the expansion of the adsorption force can be made closer to continuous expansion from stepwise expansion. Therefore, in consideration of manufacturing problems of the suction plate 34, the number of divisions of the suction area is preferably in the range of 3-10.

  FIG. 9 shows one mode of the suction plate 34 divided into three suction regions, and the suction force of the suction surface 38 for holding the resin film 18 holds a plurality of suctions so as to expand from the peripheral portion to the central portion of the resin film 18. It is a case where it is divided into areas. 10 is a cross-sectional view of the suction plate 34 of FIG. 9 cut in the lateral direction.

  As shown in FIGS. 9 and 10, the suction plate 34 is formed in a hollow rectangular parallelepiped shape, a suction surface 38 formed of a porous plate is formed on the lower surface of the suction plate 34, and a vacuum device (shown in FIG. The connection pipe 40 connected to (a) is connected.

  As the porous plate, it is sufficient that the resin film 18 can be adsorbed to the adsorption surface 38 by suction, and, for example, a plate in which many fine through holes are formed, a plate made of sintered metal, or the like can be used. The size of the adsorption surface 38 is formed to be equal to the size of the resin film 18.

  In the present embodiment, the shape of the resin film 18 is described as a square plate, so the suction surface 38 of the suction plate 34 is a square, but the shape of the resin film 18 is a disc. Is preferably in the shape of a disc.

  Inside the suction plate 34, two square tubular partition walls 42, 42 having different sizes are annularly disposed between the suction surface 38 and the upper surface 44, and the hollow interior of the suction plate 34 is three annular. It is divided into spaces 43A, 43B and 43C (see FIG. 10).

  And, on the upper surface 44 of the suction plate 34, connecting pipes 40A, 40B, 40C are provided corresponding to the three annular spaces 43A, 43B, 43C, respectively, and the connecting pipe 40A, 40B, 40C leads to the vacuum device. The pressure hoses 46 (46A, 46B, 46C) are connected. In addition, each connecting pipe 40 is provided with an open / close valve 48 (48A, 48B, 48C), and each open / close valve 48 is connected to the control means 35 (see FIG. 8) by a signal cable or wirelessly.

  The pressure hose 46 is formed of a flexible material so as not to inhibit the separation movement of the suction plate 34.

  As a result, an adsorption plate 34 is formed in which the adsorption force of the adsorption surface 38 for adsorbing and holding the resin film 18 is divided into three annular adsorption areas so as to be expanded from the peripheral portion to the central portion of the resin film 18. Here, among the three annular adsorption areas formed on the adsorption surface 38 of the adsorption plate 34, the outermost adsorption area is the peripheral adsorption area 38A, the second adsorption area is the intermediate adsorption area 38B, and the central adsorption area is It will be called central adsorption area 38C (see FIGS. 8 and 9).

  FIG. 11 shows another mode of the suction plate 34 divided into three suction regions, and a plurality of suction forces of the suction surface 38 for holding the resin film 18 can be expanded from opposite end portions to the central portion of the resin film 18. It is a case where it is divided into the adsorption area of. 12 is a cross-sectional view of the suction plate 34 of FIG. 11 cut in the lateral direction.

  As shown in FIGS. 11 and 12, the suction plate 34 is formed in a hollow rectangular parallelepiped shape as in FIGS. 9 and 10 described above, and the suction surface 38 formed of a porous plate is formed on the lower surface of the suction plate 34. A connecting tube 40 is provided, which is formed and connected to the upper surface 44 to a vacuum device (not shown). The specific example of the porous plate and the size and shape of the adsorption surface are also the same as those described in FIGS.

  Inside the suction plate 34, four square partition-shaped partition plates 52 are disposed in parallel between the suction surface 38 and the upper surface 44, and the hollow interior of the suction plate 34 has five parallel spaces 53A to 53E (see FIG. (See 12). Then, on the upper surface 44 of the suction plate 34, three connecting pipes 40 (40A, 40B, 40C) are provided for five parallel spaces 53A to 53E (see FIG. 12). That is, one connecting pipe 40A connecting the both end spaces 53A and 53E of the five parallel spaces 53A to 53E in the communication state is provided, and one connection connecting the second spaces 53B and 53D from the both ends in the communication state The pipe 40B is provided, and one connecting pipe 40C is provided in the middle space 53C. Then, flexible pressure resistant hoses 46 (46A, 46B, 46C) leading to the vacuum device are connected to the respective connection pipes 40. In addition, each connecting pipe 40 is provided with an on-off valve 48 (48A, 48B, 48C), and the on-off valve 48 is connected to the control means 35 by a signal cable or wirelessly.

  As a result, a suction plate 34 is formed in which the suction surface 38 for holding the resin film 18 by suction is divided into three suction regions so as to be able to expand from the opposite ends of the resin film 18 to the central portion.

  Referring back to FIG. 8, the separating means 36 is a portal frame 58 formed of a pair of columns 54, 54 erected on both sides of the suction plate 34 and beams 56 installed on the pair of columns 54; A pair of nut members 60, 60 projecting laterally from both ends of the suction plate 34, and a pair of nut members 60, 60 are held by the pair of columns 54, 54 so as to be slidably supported. Linear bearings 62, 62, a pair of servomotors 64, 64 mounted on the beam 56 of the portal frame 58, and a pair of ball screws 66, 66 screwed to the nut member 60 and rotationally driven by the servomotor 64. Configured The pair of servomotors 64 are connected to the control means 35 by signal cables or wirelessly.

  The control means 35 is mounted on the beam 56 of the portal frame 58 and controls opening and closing of the three on-off valves 48 provided on the connecting pipe 40 of the suction plate 34, and a pair of servomotors 64 provided on the separating means 36. It performs ON-OFF control and control of rotation speed etc.

  The control means 35 controls the opening and closing control of the three on-off valves 48 of the suction plate 34 and the on-off control of the servomotor 64 of the separating means 36 to obtain the following three (a), (b) and (c). Perform any of the peeling control methods.

  (A) A peeling control method of performing an adsorption area expansion step while maintaining a constant state in which the resin film 18 and the convex original plate 10 are relatively separated in the separation step.

  (B) A separation control method in which the separation step and the adsorption area enlargement step are performed simultaneously and in parallel.

  (C) A separation control method in which the separation step and the adsorption area enlargement step are alternately performed a plurality of times.

  Programs based on the above three peeling control methods (a), (b) and (c) may be stored in the control means 35 in advance.

  The fixing plate 39 holds the lower surface of the convex original plate 10 by suction to fix the convex original plate 10 so as not to move at the time of peeling. A large number of suction holes 39A are bored in the inside from the upper surface of the fixed plate 39, and the large number of suction holes 39A are connected to a vacuum device (not shown) via a communication passage 39B and a pressure resistant hose 39C.

  The separating means 36 is not limited to the above configuration of the ball screw mechanism, and it is possible to precisely separate the suction plate 34 from the convex original plate 10 by a short separation distance (about 20 to 100 mm depending on the size of the original plate 10). Such means may be used. In addition, the suction plate 34 may be fixed to move the convex original plate 10 apart. Further, the fixing plate 39 for fixing the convex original plate 10 is not limited to the adsorption and fixing, and may be one that sucks through a porous material or is fixed by a clamp or the like.

[Method of manufacturing inverted mold]
Next, a method of manufacturing the reverse mold 20 will be described. Among the steps constituting the method of manufacturing the reverse mold, the steps of preparing the convex original plate, applying the resin solution for mold, and solidifying the resin film were described in the method of manufacturing the functional sheet described above. Therefore, the peeling process using the above-described peeling apparatus 50 will be described here.

  FIG. 13 is an example of the large-area resin film 18, and is an example of the arrangement of the needle-like concave portions 22 transferred from the convex original plate 10 to the resin film 18. On the resin film surface, unit groups of the needle-like concave portions 22 two-dimensionally arranged in 4 × 4 are formed in a grid of 4 rows × 4 rows. The area of the resin film 18 increases as the number of the needle-like concave portions 22 and the number of lattices of the unit group increase. In this case, it is preferable that the peripheral portion of the resin film 18 have a non-transfer region which does not have the needle-like concave portion 22.

<Peeling process>
14 to 19 are step diagrams of the peeling process, and among the above-described three peeling control methods by the peeling device 50, the method (a) will be described. Further, in the suction plate 34, the suction surface 38 holding the resin film 18 shown in FIGS. 9 and 10 is divided into three suction regions 38A, 38B and 38C so that the suction portion 38 can expand from the peripheral portion to the central portion of the resin film 18 The case of the suction plate 34 will be described. The arrows described in the suction plate 34 of FIGS. 14 to 19 mean the suction area where the suction force is generated among the suction areas 38A, 38B, 38C obtained by dividing the suction surface 38 into three.

  Further, as a material of the resin film 18, an example of a silicone resin in which the resin film 18 after being solidified has elasticity will be described. When the elasticity of the resin film 18 is Young's modulus, it is preferably 300 MPa or less, more preferably 100 MPa or less.

  As shown in FIG. 14, the control means 35 opens the on-off valve 48A to apply an adsorption force to the peripheral adsorption area 38A of the three annular adsorption areas of the adsorption surface 38 of the adsorption plate 34, and the peripheral edge of the resin film 18 The portion 18A is held by suction.

  Then, the control means 35 rotationally drives the servomotor 64 of the separation means 36 such that the suction plate 34 is separated from the convex original plate 10.

  Thereby, as shown in FIG. 15, the suction plate 34 is separated from the convex original plate 10, so that the peripheral portion 18A of the resin film 18 is first peeled off. Here, it is needless to say that the adsorption power of the suction plate 34 to the resin film 18 is larger than the adhesion between the convex original plate 10 and the resin film 18.

  Then, as shown in FIG. 16, the control means 35 stops the rotational drive of the servomotor 64 after separating the suction plate 34 from the convex original plate 10 by a predetermined distance L. Thus, in the separation step of separating the suction plate 34 from the convex original plate 10, as shown in FIG. 16, the vicinity of the peripheral portion 18A of the resin film 18 is peeled off.

  In peeling in the vicinity of the peripheral portion 18A of the resin film 18, when the resin film 18 is a silicone resin having elasticity, the resin film 18B in the air portion is stretched when adsorbed by the suction plate 34, and A peeling operation of peeling from the convex original plate 10 is performed when elongation is to be contracted. As described above, by utilizing the force by which the resin film 18 tends to shrink as the peeling force, no excessive peeling force is applied to the peeling portion between the resin film 18 and the convex master 10, so that peeling failure can be further prevented. .

  In this case, the predetermined distance L for separating the suction plate 34 and the convex original plate 10 and the speed for separating them are the removability of the resin film 18 from the convex original plate 10, the elasticity of the resin film 18, the thickness of the resin film 18 It is preferable to set in advance by a preliminary test or the like in consideration of the peeling characteristics such as the size and size of the needle-like concave portion to be transferred.

  Next, as shown in FIG. 17, the control means 35 opens the on-off valve 48B and holds the suction force on the intermediate suction area 38B in a state in which the separation distance between the suction plate 34 and the convex original 10 is maintained at a predetermined distance L. Grant That is, the suction area of the resin film 18 with respect to the suction surface 38 of the suction plate 34 is expanded stepwise from the peripheral portion toward the central portion.

  Thereby, as shown in FIG. 18, the peeling area of the resin film 18 peeled from the convex original plate 10 is expanded toward the central portion. Also in this case, when the resin film 18 is a silicone resin having elasticity, the resin film 18 is peeled off from the convex original plate 10 by the same peeling operation as described above.

  Next, as shown in FIG. 19, the control means 35 opens the on-off valve 48C in a state in which the separation distance between the suction plate 34 and the convex original plate 10 is maintained at a predetermined distance L, and attracts the central suction area 38C. Grant That is, the suction force is applied to the entire suction surface 38 of the suction plate 34. Thereby, the entire surface of the resin film 18 is peeled off from the convex original plate 10. Also in this case, when the resin film 18 is a silicone resin having elasticity, the resin film 18 is peeled off from the convex original plate 10 by the same peeling operation as described above.

  In addition, the outline | summary in the case of the peeling control method of said (b) which performs a separating process and an adsorption area expansion process simultaneously in parallel using said peeling apparatus 50 is as follows. That is, the control means 35 opens the on-off valve 48A, the on-off valve 48B and the on-off valve 48C of the adsorption plate 34 in order to expand the adsorption area of the resin film 18 stepwise from the peripheral part to the central part. By controlling 36, the resin film 18 and the convex original plate 10 are separated little by little so that the predetermined distance L is obtained in the final peeling state. The predetermined distance L in this case may be different from the predetermined distance L in the peeling control method of (a).

  Moreover, the outline | summary in the case of the peeling control method of said (c) which performs a separation | isolation process and an adsorption area expansion process alternately several times using said peeling apparatus 50 is as follows. That is, when the control means 35 opens the on-off valve 48A of the suction plate 34 and adsorbs the peripheral portion 18A of the resin film 18, the control means 35 is controlled to control the predetermined peeling state between the resin film 18 and the convex master 10. It is separated to 1/3 of the distance L. Next, the control means 35 opens the on-off valve 48B of the suction plate 34 and separates the suction region of the resin film 18 stepwise from the peripheral portion 18A to the central portion to 2/3 of the predetermined distance L. Next, the control means 35 opens the on-off valve 48C of the suction plate 34 and separates the suction area of the resin film 18 from the peripheral portion 18A to the central portion while separating it to a predetermined distance L. Here, the reason why the predetermined distance L is separated in three steps is because it is divided into three suction areas 38A, 38B, and 38C corresponding to the three open / close valves 48, and the number of floors to be separated is set according to the number of divisions. be able to. Further, the predetermined distance L in this case may be different from the predetermined distance L in the peeling control method of (a) and the predetermined distance L in the peeling control method of (b).

  Moreover, although the example of the suction plate 34 demonstrated by FIG.9 and FIG.10 was demonstrated as the suction plate 34, it is fundamentally the same also in the case of the suction plate 34 demonstrated by FIG.11 and FIG.12.

  Moreover, although the peeling apparatus 50 shown by FIGS. 9-12 is an example of the adsorption | suction board 34 comprised so that the adsorption | suction area | region of the adsorption surface 38 might be expanded in steps, the adsorption area of the adsorption surface 38 was continuously made. In the case of enlargement, for example, the suction plate 34 can be configured as follows.

  FIG. 20 is a conceptual diagram showing an aspect of the configuration of the suction plate 34 configured to continuously expand the suction region of the suction surface 38, and is a view of the suction plate 34 as viewed from the suction surface 38 side. .

  As shown in FIG. 20, the suction plate 34 is formed in a hollow rectangular solid shape, and a suction surface 38 formed of a porous body is formed on the lower surface of the suction plate 34. A triangular thin plate 68 is brought into contact with the suction surface 38, and the suction surface 38 is closed by the thin plate 68 except for the opposite end portions (triangular end portions in FIG. 20) of the suction surface 38.

  Then, as shown by 100A, 100B, and 100C in FIG. 21, the triangular thin plate 68 is slid while being held in contact with the suction surface 38, and is shifted so as to make the blocked portion of the suction surface 38 smaller. Thus, the suction area of the suction surface 38 is configured to continuously expand in the central portion.

  Although the means for sliding the thin plate 68 is not shown, a method of connecting the support portion 70 of the thin plate 68 to, for example, a ball screw mechanism or a cylinder mechanism can be employed. The thin plate 68 is preferably thin, but when the thin plate 68 is supported by the support portion 70, it is necessary that the thin plate 68 has a rigidity enough to bend and hang down so as not to be separated from the suction surface 38. As the thin plate 68, for example, a metal plate or rigid resin can be employed.

  FIG. 22 is another embodiment of the suction plate 34 which continuously enlarges the suction area of the suction surface 38, in which two triangular thin plates 68A, 68B facing the suction surface 38 are interviewed and two thin plates 68A, The suction surface 38 is configured to be closed by the thin plates 68A and 68B, leaving both end portions of the suction surface 38 such that the adjacent sides of the 68B are in contact with each other.

  In this case, as shown by 150A and 150B in FIG. 22, the two thin plates 68A and 68B whose sides are in contact with each other are slid in directions away from each other while being in contact with the suction surface 38. Thus, the suction area of the suction surface 38 is continuously expanded to the central portion.

  As described above, according to the method of manufacturing a reverse mold according to one embodiment of the present invention, the adsorption area of the resin film 18 with respect to the adsorption plate 34 is stepwise or continuously from the peripheral portion or opposite end portions to the central portion. Then, the resin film 18 is peeled off from the convex original plate 10 by spreading. Thereby, the separation distance between the already peeled (already peeled) resin film portion adsorbed and held by the suction plate 34 and the unpeeled (not yet peeled) resin film portion in close contact with the convex original plate 10 In the short state, it is possible to realize the exfoliation until the final exfoliation. That is, the resin film 18B in the air portion existing in the air between the suction plate 34 and the convex master 10 can realize peeling until final peeling in a short state.

  Therefore, it is possible to effectively prevent the resin film 18 from being torn due to the resin film 18 being pulled too long (the resin film 18B in the air portion becomes too long) even in the final peeling stage.

  Also, when peeling the resin film 18 from the convex master 10, the resin film 18 is convex so as not to damage or damage the needle concave 22 of the resin film 18 or the needle convex 12 of the convex master 10. It is preferable to peel off the mold original plate 10 in a direction as vertical as possible. However, since the resin film 18 and the convex original plate 10 are in close contact with each other at a large contact area ratio, it is extremely difficult to separate the entire surface of the resin film 18 in the vertical direction with respect to the convex original plate 10 at once. If it is attempted to peel off with a large force, peeling failure will occur. In particular, as shown in FIG. 13, in the case of a large-area resin film 18, it is extremely difficult to separate the entire surface of the resin film 18 in a direction perpendicular to the convex original plate 10 at one time.

  However, as in the present invention, the resin film 18 is exfoliated from the convex master 10 by expanding the adsorption region of the resin film 18 to the adsorption plate 34 stepwise or continuously from the peripheral edge or opposite both ends to the central portion. As a result, the resin film 18 is gradually peeled off substantially vertically in each part, so that peeling can be performed with a small peeling force. As a result, since an excessive peeling force is not applied to the needle-like concave portions 22 of the resin film 18 and the needle-like convex portions 12 of the convex original plate 10, the needle-like concave portions of the resin film 18 and the needle-like convex portions of the convex original 10 12 can be peeled without damaging or damaging, and the peeling speed can be increased.

  Further, the resin film 18 is peeled from the convex original plate 10 by expanding the adsorption region of the resin film 18 with respect to the adsorption plate 34 stepwise or continuously from the peripheral portion or both opposing ends to the central portion. Peeling can be completed in a short time as compared with the case of peeling from one end to the other end of.

  As a result, the resin film 18 having the fine needle-like concave portions 22 to which the fine needle-like convex portions 12 are transferred can be peeled quickly from the convex master 10 without peeling defects. In addition, since the reverse mold 20 can be manufactured rapidly without defective peeling, the yield and the production efficiency are improved, which also contributes to the reduction of the manufacturing cost.

  Furthermore, in the case of using, for example, silicone resin having elasticity as the resin film 18, the adsorption area of the resin film 18 to the adsorption plate 34 is expanded stepwise or continuously from the peripheral portion or opposite end portions to the central portion. In the course of the process, the resin film having elasticity is in a state in which the resin film in the air part between the suction plate and the convex master is stretched, and is peeled from the convex master 10 when its elongation is reduced. As described above, by utilizing the force by which the resin film 18 tends to shrink as the peeling force, no excessive peeling force is applied to the peeling portion between the resin film 18 and the convex master 10, so that peeling failure can be further prevented. .

  Moreover, peeling at the time of manufacture of a reversal mold can be automated by using peeling apparatus 50 mentioned above.

  In the present embodiment, although the peeling method which is the feature of the present invention is applied to the peeling step in manufacturing the reverse mold, the peeling method between the polymer film 28 and the reverse mold 20 in manufacturing the functional sheet is performed. It may apply.

DESCRIPTION OF SYMBOLS 10 convex type original plate 12 needle-like convex part 14 spacer 16 resin for molds 18 resin film 20 reverse mold 22 needle-like concave part 24 polymer solution for functional sheet 26 spacer 28 polymer film 30 functional sheet 32 microneedle 34 suction plate 35 Control means 36 Separating means 38 Suction surface 39 Fixing plate 40 Connecting pipe 42 Partition plate 44 Upper surface 46 Pressure hose 48 Opening and closing valve 50 Peeling device 52 Partition plate 54 Column 56 Beam 58 Portal frame 60 Nut member 62 Linear bearing 64 Servo motor 66 Ball screw 68 triangle sheet 70 support

Claims (10)

A step of producing a convex original plate in which a plurality of fine needle-like convex portions are arranged in an array, and a resin obtained by applying and solidifying a resin for molding to the convex original plate and transferring the needle-like convex portions In a method of manufacturing a reverse mold having a needle-like concave portion in which the needle-like convex portion is reversed by the step of forming a film, and the step of peeling the resin film from the convex master.
The peeling process of peeling the resin film from the convex original plate is
A suction plate is provided on the opposite side of the convex original plate of the resin film,
Separating the resin film from the convex original plate by holding the peripheral portion or opposite end portions of the resin film by suction on the suction plate;
An adsorption area expansion step of expanding the adsorption area of the resin film with respect to the adsorption plate stepwise or continuously from the peripheral part or opposite end parts to the central part in a stepwise manner.   The method for manufacturing a reverse mold according to claim 1, wherein the adsorption area enlargement step is performed while maintaining a constant state in which the resin film and the convex original plate are relatively separated in the separation step.   The method for manufacturing a reverse mold according to claim 1, wherein the separation step and the adsorption area enlargement step are performed simultaneously in parallel.   The method for manufacturing a reverse mold according to claim 1, wherein the separation step and the adsorption area enlargement step are alternately performed a plurality of times.   The method for producing a reverse mold according to any one of claims 1 to 4, wherein the resin film after solidifying the resin has elasticity.   The method for manufacturing a reverse mold according to claim 5, wherein the resin film is a silicone resin.   The manufacturing method of the inversion mold in any one of Claim 1 to 6 which has a non-transfer area | region in the peripheral part of the said resin film, or the said opposing both ends. A polymer solution applying step of applying a polymer solution for a functional sheet to a reverse mold produced by the production method according to any one of claims 1 to 7;
A polymer solution solidifying step of solidifying the polymer solution applied in the polymer solution applying step to form a polymer film;
A peeling step of peeling the polymer film solidified in the polymer solution solidifying step, and a method of producing a functional sheet. A convex original plate in which a plurality of fine needle-like convex portions are arranged in an array, and a resin film on which resin for molding is applied to the convex original plate and solidified to transfer the needle-like convex portions In the peeling apparatus for peeling,
An adsorbing plate provided on the opposite surface of the convex original plate of the resin film and divided into a plurality of adsorbing regions so that the adsorptive power of the adsorptive surface can be expanded stepwise from the peripheral portion or opposite ends of the resin film to the central portion When,
Separating means for relatively separating the suction plate and the convex original plate;
And a control unit configured to control the suction plate and the separation unit. A convex original plate in which a plurality of fine needle-like convex portions are arranged in an array, and a resin film on which resin for molding is applied to the convex original plate and solidified to transfer the needle-like convex portions In the peeling apparatus for peeling,
A suction plate having a suction surface on the surface opposite to the convex original plate of the resin film;
By closing the suction surface while leaving the opposite ends of the suction surface facing each other by interviewing the suction surface, and sliding the contact surface while making the suction surface contact, the blocked portion of the suction surface is made smaller A thin plate configured such that the suction area of the suction surface is continuously expanded in the central portion;
Separating means for relatively separating the suction plate and the convex original plate;
And a control unit configured to control the suction plate, the thin plate, and the separation unit.

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