KR20100018945A - Metal-soft mold and method for fabricating the same - Google Patents

Abstract

PURPOSE: A metal coating soft mold using a base sheet having flexibility and a manufacturing method thereof is provided to increase the durability and to reduce the manufacturing cost by coating a base sheet with metal material and a metal compound. CONSTITUTION: A metal coating soft mold comprises a base sheet, and a metal material or the metal compound. A pattern is formed in the base sheet. The surface of the base sheet is coated with metal or the metal compound. The base sheet is included of the polymer and made by coating the upper side of a substrate(130) of a film material with thermosetting resin and a photocurable resin(120).

Description

Metal-coated soft mold and its manufacturing method {METAL-SOFT MOLD AND METHOD FOR FABRICATING THE SAME}

The present invention relates to a metal-coated soft mold used in the process of forming a sheet on which a pattern using a film-based substrate is formed. In particular, the present invention is applied to a metal-coated soft mold that can be coated with a metal or metal compound on the sheet on which an arbitrary pattern is formed to improve the durability of the mold and to prevent deformation such as shrinkage or expansion of the material even after use. It is about.

Apparatus and manufacturing apparatus of optical member having fine shape which can improve handling and yield in continuous mass production of optical member having various micro shape of micro or nano scale, which is used in display or optical element which is recently attracting attention. There is a growing interest in methods and molding molds for the same.

In particular, the typical ones widely used as optical members in display devices include plates, films, sheets, and the like for diffusion or condensation used in LCDs. More specifically, such an optical member is used in a backlight unit used in an LCD, and the backlight unit includes a light source, a light guide plate or a diffusion plate, a diffusion sheet, a prism sheet, and the like. In addition to the reflective sheet, a mold frame, a protective sheet is further provided.

Many of these optical sheets are components that allow light to be emitted so that the characteristics of light generated from an edge method or a direct method influence the quality of an image, and thus have uniform and high brightness characteristics.

To this end, optical sheets such as diffusion sheets and prism sheets are combined. As such, the manufacture of the optical sheet is mainly manufactured by using a mold.

That is, the shaping | molding method using a metal mold | die is mainly used for the method of manufacturing an optical film or a plate. Mold production is an important factor for producing optical sheets.

Existing techniques for making molds can be classified into three categories. (1) using a mechanically processed pattern master directly as a mold, (2) a stamper processing method using a metal film electroplated using the pattern master as a base material, and (3) using the above method. There is a method of using a sheet molded with a special resin as a soft mold. FIG. 1A illustrates a machined circular mold, and FIG. 1B illustrates a mold of an electroplated metal film.

In the case of the direct processing method using the pattern master described above, the pattern shape is mechanically processed on a cylindrical metal surface, and the pattern processed mold is directly mounted on the manufacturing apparatus, and then a material having easy formability is formed between the substrate and the mold. It is a method of injecting and curing it to continuously transfer / apply the shape of the mold surface onto the substrate.

In addition, the stamper processing method is to continuously transfer / apply the shape of the stamper mold onto the substrate by fixing the stamper tightly to the cylindrical metal support surface and then injecting and curing a moldable material between the substrate and the stamper mold. That's the way. In this case, as a method of curing the coating material, heat is directly applied to the mold in order to increase the transferability, and sometimes a material that cures in response to UV ultraviolet rays has been used.

In addition, the soft mold method is a method using a sheet molded with a special resin using a conventional mold manufactured by the above two methods as a mold.

However, the above conventional technology has the following problems.

First, the machine operation is difficult to realize the shape of the clean pattern as the size of the pattern is smaller, the cost increases significantly and takes longer as the overall processing area is wider.

Next, when the stamper mold is manufactured by electroplating, the stamper manufacturing process of the pattern is not only difficult but also difficult to handle due to the rigid hardness of the produced metal mold, and the unit cost of the raw material of electroplating. Due to the high cost, the production cost is high.

Finally, soft molds made of special resins are made of organic materials, which are flexible and easy to handle, but the surface hardness of the special resins is low, resulting in poor durability and shrinkage or expansion when used several times.

The present invention has been made to solve the above problems, an object of the present invention by coating a base sheet on which a pattern is formed using a metal or a metal compound, to reduce the manufacturing cost of the mold, improve the durability, It is to provide a metal-coated soft mold that can promote the ease of manufacturing process due to the flexibility of the base sheet.

In order to solve the above problems, the present invention improves the durability of the mold by coating a sheet having an arbitrary pattern with a metal or a metal compound, and in particular, the base sheet is a polymer material or a curable resin formed on a film substrate. It can be used, and the shape of the various patterns are arranged in various arrangements, in particular the metal or metal compound to be coated to a thickness of 100 nm ~ 1㎛.

According to the present invention, by coating a base sheet on which a pattern is formed using a metal or a metal compound, it is possible to reduce the manufacturing cost of the mold, improve durability, and increase the ease of manufacturing process due to the flexibility of the base sheet. There is an effect that can provide a metal coating soft mold.

The present invention provides a metal-coated soft mold coated with a metal or a metal compound on the surface of a patterned base sheet, thereby improving the durability of the mold, making it easy to manufacture and handle, and reduce raw material costs. This can be reduced.

In another aspect, the present invention provides a metal coating soft mold, characterized in that the base sheet is made of a high molecular material or a thermosetting or photocurable resin is formed on the substrate of the film substrate, the durability of the formed mold To ensure that

In addition, the metal or metal compound of the present invention may be selected from at least one selected from Fe, Ni, Cu, Al, Cr, or a compound thereof, and by using this coating, to ensure the durability of the metal coating soft mold Thus, even after use, deformation such as shrinkage or expansion of the material can be suppressed.

In addition, the present invention is to provide a metal-coated soft mold, characterized in that the pattern formed on the base sheet is formed in an embossed or intaglio shape, the pattern of the same shape or different shape is arranged regularly or irregularly. . This has the advantage of providing a robust mold of various formations.

In addition, the present invention provides a metal-coated soft mold, wherein the pattern is any one selected from polygonal horns, polygons, spheres, ovals, lenticulars, prisms, or a combination thereof. To ensure the diversity of manufacturing patterns.

In addition, the present invention is to provide a metal-coated soft mold, characterized in that the metal or metal compound coated on the base sheet is coated with a thickness of 100nm ~ 1㎛.

In addition, the present invention in the manufacture of the mold described above, 1) molding the base sheet; 2) coating a metal or a metal compound on the molded base sheet; It is possible to provide a method of manufacturing a metal-coated soft mold comprising a, and while ensuring easy workability through a flexible sheet material, can reduce the raw material cost, and manufacture a durable mold Do it.

In addition, the present invention, the step 1) of the above-described manufacturing step, the metal coating soft, characterized in that the step of forming a pattern using a metal mold in the base sheet, the curable resin is formed on the substrate of the film substrate It is possible to provide a method for manufacturing a mold.

In addition, the present invention provides a method of manufacturing a metal coating soft mold, characterized in that the metal mold is a metal mold formed by machining or electroplating, it is possible to use the existing metal mold as it is Ensure ease of operation.

 In addition, the present invention is a manufacturing method of the metal coating soft mold, characterized in that the coating method of the step 2) is performed by any one selected from the vacuum deposition method, electroless plating method, spray method. By providing a variety of manufacturing methods, and to prevent the occurrence of foreign matter on the surface to be coated and to evenly coat the surface to improve the quality of the manufactured product.

In addition, the present invention provides a method of manufacturing a metal-coated soft mold, characterized in that the thickness of the coating is coated with a thickness of 100 nm ~ 1㎛ in the above-described manufacturing step, according to the specifications of the final product Allow various coatings.

Hereinafter, with reference to the accompanying drawings will be described the configuration and operation of the present invention.

Referring to FIG. 2, FIG. 2 is a view illustrating a manufacturing process of a metal coating soft mold and a process of forming a final product using the same.

First, in step S 1 and S 2 to form the base sheet (120, 130) using an existing mold (mold) (110). The existing mold (mold) refers to a mold made by machining or electroplating, and particularly preferably made of a metal material.

The base sheet may be made of a polymer material, and more preferably, as shown, a form in which a curable resin 120 is stacked on an upper surface of a substrate 130 of a plastic substrate such as a film substrate, such as PET or PMMA. Can be used.

As the curable resin used herein, a thermosetting resin, a photocurable resin, or the like may be used, which is a photocurable resin cured by a light source such as a ultraviolet ray such as a thermosetting resin such as phenol, urea, melamine, polyurethane, alkyd resin, or the like. Those such as resin compositions and the like can be applied thereto.

After molding using the existing mold, the curable resin has a shape opposite to that of the existing mold. The shape of the pattern formed on the base sheet may have an intaglio or embossed form, and may be formed of any one selected from polygonal horns, polygons, spheres, ellipses, lenticulars, and prisms, or a combination thereof. have. That is, the arrangement of the pattern may constitute the entire pattern in any one of the same shape, it may be made of a combination of several shapes.

Next, in step S3, the surface of the molded base sheets 120 and 130 is coated with a metal or a metal compound.

The metal or metal compound that can be used herein may be any metals capable of being deposited, and for example, at least one selected from Fe, Ni, Cu, Al, Cr, or a compound thereof is applicable.

As a method of coating, vacuum evaporation may be used. Vacuum deposition is a method of forming a film by heating and evaporating a substance in a vacuum and then depositing the evaporate on the surface of another substance. Generally, a vacuum deposition method using resistance heat according to heating or externally supplied energy source, electron beam There is a vacuum deposition method using, and the like, may be used in the present invention. Using such a vacuum deposition method does not generate foreign matter on the surface, there is an advantage that the coating is even, there is an advantage that the quality of the mold and the quality of the product is improved.

In addition, an electroless plating method may be used as another coating method.

Electroless plating is a method of coating a plated metal on the surface of a product by using a reduction reaction in a solution. It is possible to plate widely from metal to nonmetal, and the precision after plating is extremely high. It is widely used. In the present invention, a metal or a metal compound may be coated on the surface of the pattern by the electroless plating method. In case of coating by electroless plating method, electrodeposition property is uniform. The non-conductive material also has the advantage of ensuring good adhesion. In addition, as another coating method, a spray method of coating by spraying a metal or nonmetallic compound in the form of a spray may be used.

In this case, the thickness of the coating in the above-described process can be adjusted by coating in the range of 100nm ~ 1㎛ in consideration of the specifications of the final product. Especially preferably, it forms in 100-200 nm. This coating layer should be formed in a uniform thickness in the flat layer between the curved layer and the lens corresponding to the lens in the mold, it is preferable to form a thin when considering the material ratio of the metal to be coated.

However, considering the film adhesion between the resin layer and the coating layer, in order to improve the durability of the mold should be coated with at least 100nm. In addition, when the coating layer is 1 μm or more, the thickness uniformity of the coating layer is lowered, and since the metal is coated on the shape formed on the photocurable resin 120 with the existing mold 110, it is difficult to design a shape having a desired size. It is because it is desirable to form 1 micrometer or less.

Steps S 4 and S 5 illustrate the production of the product using the coated base sheet as a mold. The metal-coated soft mold according to the present invention formed in the step S4 is to be used for sheet production in the form of a sheet or wound in a cylinder.

To describe the specific process, the photocurable resin (UV resin) 150 is injected between the base substrate 160 and the soft mold according to the present invention manufactured in step S4, and then, when irradiated with UV, it is shown in step S5. The same optical sheet is made. In one embodiment of the present invention, the photocurable resin (UV) resin is injected as an example, but basically it is also possible to use the curable resin 120 used when manufacturing the soft mold. In addition, the substrate of the optical sheet should be basically optically transparent, and basically can be used a plastic substrate of the material used as the substrate 130 of the soft mold.

The optical sheet, which is the final product formed in step S5, illustrates a sheet form having an upper surface opposite to the shape of the mold formed in this embodiment.

The optical sheet thus manufactured is applied to a backlight unit such as an LCD to diffuse and collect light from a light source to improve brightness uniformity and brightness, thereby providing a backlight unit having higher light efficiency.

In the detailed description of the invention as described above, specific embodiments have been described. However, many modifications are possible without departing from the scope of the invention. The technical spirit of the present invention should not be limited to the described embodiments of the present invention, but should be determined not only by the claims, but also by those equivalent to the claims.

Figure 1 schematically shows the structure of a conventional mold.

2 is a process chart showing a process of manufacturing a metal soft mold and a product using the same according to the present invention.

Claims (13)

Metal-coated soft mold coated with a metal or metal compound on the surface of the patterned base sheet (base sheet). The method according to claim 1, The base sheet is made of a polymer material or a metal coating soft mold, characterized in that the thermosetting resin or photocurable resin is formed on the substrate of the film base. The method according to claim 2, The metal or metal compound is at least one selected from Fe, Ni, Cu, Al, Cr, or a compound thereof, the metal coating soft mold. The method according to claim 3, The pattern is formed in the shape of an embossed or intaglio, A metal-coated soft mold, characterized by regular or irregular arrangement of patterns of the same shape or of different shapes. The method according to claim 3, The pattern of the metal coating soft mold, characterized in that formed of a combination of one selected from the shape of polygonal, polygonal, spherical, oval, lenticular, prism. The method according to any one of claims 1 to 5, The metal or metal compound is a metal coating soft mold, characterized in that the coating in a thickness of 100nm ~ 1㎛. 1) molding the base sheet; 2) coating a metal or a metal compound on the molded base sheet; Method of producing a metal-coated soft mold comprising a. The method according to claim 7, The step 1) is a method of manufacturing a metal-coated soft mold, characterized in that for forming a pattern on the base sheet formed with a thermosetting or photo-curable resin on the substrate of the film substrate using a metal mold. The method according to claim 8, The metal mold is a metal coating soft mold manufacturing method, characterized in that the metal mold is formed by machining or electroplating. The method according to claim 9, The coating method of step 2) is a method of manufacturing a metal coating soft mold, characterized in that carried out by any one selected from vacuum deposition method, electroless plating method, spray method. The method according to any one of claims 8 to 10, The pattern is a method of manufacturing a metal coating soft mold, characterized in that the coating of a thickness of 100nm ~ 1㎛. A metal-coated soft mold coated with a metal or metal oxide on an anticorrosion portion of a base sheet on which a curable resin is formed on an upper substrate of a polymer material or a film substrate; A method of manufacturing an optical sheet using a metal coating soft mold, characterized in that the optical coating is prepared by injecting and curing a curable resin between the metal coating soft mold and the optical sheet substrate. A metal-coated soft mold coated with a metal or metal oxide on an anticorrosion portion of a base sheet on which a curable resin is formed on an upper substrate of a polymer material or a film substrate; The backlight unit of the LCD comprising an optical sheet prepared by injecting and curing a curable resin between the metal coating soft mold and the optical sheet substrate.

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