KR20110055439A - Roll-type micromold system and fabrication method of the same - Google Patents

Abstract

PURPOSE: A roll-shaped micromold system and a manufacturing method thereof are provided to consecutively and easily manufacture high-efficiency optical sheets and multi-functional plastic surfaces. CONSTITUTION: A manufacturing method of a roll-shaped micromold system is as follows. A micro base structure is manufactured through a Deep X-Ray Lithography process and a ultraviolet exposure process(ST1). Modules for forming a micromold is manufactured by forming a micro structure on the surface of the micro base structure through an electroplating process(ST2). A roll-shaped micromold system is formed by combining and coupling the modules(ST3).

Description

Roll-shaped micro mold system and manufacturing method thereof {ROLL-TYPE MICROMOLD SYSTEM AND FABRICATION METHOD OF THE SAME}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roll-shaped micro mold system and a method of manufacturing the same, which are applied to a mass forming technology of a roll-type micro structure, continuously forming a micro structure.

Recently, as a mass molding technology of various kinds of plastic microstructures, molding techniques such as micro injection molding and hot embossing have been researched and developed. Through these molding technologies, applications for microstructures such as high integration, high efficiency and high functionality are being developed / produced. In addition, a roll molding technology has been developed for mass forming technology of a highly productive microstructure. The mass forming technology of the roll-type micro structure has a high productivity compared to other forming technologies because the final molded product is continuously molded.

In the mass forming technology of such a microstructure, it is essential to precisely manufacture a mold or a mold insert having a shape opposite to the final molded product. In order to improve the dimensional accuracy and productivity of the final molded product, it is necessary to manufacture a precise and rigid mold. Accordingly, molds for forming a microstructure having a complicated shape are manufactured by using manufacturing techniques such as micro precision machining, micro discharge processing, and laser machining. However, such direct fabrication techniques have a high degree of freedom in shape, but require a lot of time to manufacture a mold, and have a low precision.

For example, the Liga process developed in Germany consists of a continuous process of X-ray exposure, electroplating and mass forming. Specifically, the Riga process precisely fabricates a microstructure by exposure using X-rays, produces a rigid mold by electroplating on the microstructure, and replicates the microstructure in large quantities using the mold. This Riga process overcomes the disadvantages of the conventional direct processing method. Currently, for fabricating molds for mass forming of microstructures, the Liga process is applied. The Liga process may utilize high energy X-rays or general UV-exposures generated by an emission accelerator.

The mold produced by the liga process is difficult to be directly applied to the microstructure forming technology of the roll method. That is, the exposure technique such as X-ray exposure or UV-exposure is basically easy to manufacture a planar structure, so it is difficult to directly apply to roll-shaped mold fabrication having a basic structure of cylinder shape. Therefore, the mass forming technology of the roll-type microstructure is applied to a method of manufacturing a thin metal mold including the microstructure by electroplating and winding the metal mold on a pre-fabricated roll. In addition, the mass-molding technology of the roll-type microstructure is applied to a method of forming a microstructure on a plastic substrate by pressing a roll by heating the plastic substrate and the metal mold together to form a metal mold by thinly plating to have flexibility.

The mass forming technology of such a roll-shaped microstructure is limited because of the disadvantages and limitations of the roll-shaped mold fabrication techniques. For example, the shape of the final molded part is also limited because it is difficult to manufacture a robust and precise metal mold with a complex microstructure. In addition, after fabricating a flexible plastic mold that is relatively easy to manufacture, a mass forming technology of a roll type microstructure using a photocurable plastic material having a low viscosity or a roll type printing technology using various inks is mainly developed.

One aspect of the present invention is to provide a roll-shaped micro-molding system that is applied to the mass-forming technology of the roll-type microstructures continuously forming the microstructures.

One aspect of the present invention is to provide a roll-shaped micro-molding system for forming a large-size plastic microstructure of a complex shape by applying a mass-forming technology of a roll-shaped microstructure.

In addition, one aspect of the present invention is to provide a manufacturing method for manufacturing a roll-shaped micro mold system.

In the method of manufacturing a roll-shaped micro mold system according to an embodiment of the present invention, a micro mold is formed by forming a micro structure on a surface of the parent structure by a metal electroplating process in a first step of manufacturing a micro structure by an exposure process. A second step of manufacturing a module for use, and a third step of combining and combining the modules to form a roll-shaped micro mold system.

The exposure process of the first step may be any one of a deep x-ray lithography (DXRL) process using X-rays of an emission accelerator and an exposure process using UV as a light source.

The metal electroplating process of the second step may be any one of copper electroplating, nickel electroplating and nickel alloy electroplating.

The second step may form the module having the microstructure on the surface in various thicknesses.

In the third step, the modules having various thicknesses having various microstructures may be selected, and the modules may be combined and combined to form the roll-shaped micro mold system in various structures.

Roll-shaped micro-molding system manufacturing method according to an embodiment of the present invention, the roll-shaped micro-molding module having a microstructure on the surface formed on a cylinder of a predetermined thickness, the coupling formed in the center of the module A shaft member inserted into the sphere, and a support member coupled to the shaft member at both sides of the combined and coupled modules to support the modules.

The modules may have various thicknesses with the microstructure on the surface.

The micro structure formed on the surface of the module may be formed of one of a triangle, a square and a trapezoid.

As such, one embodiment of the present invention may form microstructures having a complicated shape, and may also mass-form a microstructure of a complicated shape in a continuous process. One embodiment of the present invention facilitates the shaping of complex microstructures with a combination of various modules, and allows for the easy and continuous manufacture of highly efficient optical sheets and various functional plastic surfaces including microstructures.

1 is a flowchart illustrating a method of manufacturing a roll-shaped micro mold system according to an embodiment of the present invention.
2 is a perspective view of a roll-shaped micro mold forming module which is applied to a roll-shaped micro mold system according to an exemplary embodiment of the present invention and manufactured by exposure in a plane direction and metal electroplating.
3 is a perspective view of a combination of modules forming a microstructure of various shapes on the surface.
4 is a perspective view of a process of continuously forming a microstructure by using a roll-shaped micro mold system according to an embodiment of the present invention.
FIG. 5 is a conceptual view of manufacturing a microminiature structure by an X-ray exposure process using a radiation accelerator in the manufacturing method of FIG. 1.
6A is a perspective view of parent structures of a roll-shaped micro mold forming module manufactured by an X-ray exposure process.
FIG. 6B is a perspective view of roll-shaped micro mold forming modules manufactured by an electroplating process for the parent structure of FIG. 6A.
7A, 7B and 7C are partial perspective views of a roll-shaped micro mold forming module having triangular, square and trapezoidal microstructures on its surface.
FIG. 8A is a perspective view of a roll-shaped micro mold system manufactured by combining / combining modules for forming a micro mold having various micro structures.
8B is an enlarged partial view of FIG. 8A.
9A is a perspective view of a plastic structure prototyped using a fabricated roll-shaped micro mold system.
9B is an enlarged partial view of FIG. 9A.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art may easily implement the present invention. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In order to clearly illustrate the present invention, parts not related to the description are omitted, and the same or similar components are denoted by the same reference numerals throughout the specification.

1 is a flowchart of a method of manufacturing a roll-shaped micro mold system according to an embodiment of the present invention (hereinafter referred to as "a method of manufacturing a micro mold system" for convenience).

Referring to FIG. 1, in the method of manufacturing a micro mold system according to an exemplary embodiment, a first step (ST1) of manufacturing a micro matrix structure using an exposure process, a micro structure is formed on a surface of the matrix structure using a metal electroplating process. A second step (ST2) of forming a micro mold forming module (hereinafter referred to as "module" for convenience), and combining and combining the modules to form a roll-shaped micro mold system (hereinafter referred to as "micro mold system"). A third step ST3 of forming " "

The exposure process applied to the first step ST1 is a deep x-ray lithography (DXRL) process using X-rays of an emission accelerator or an exposure process using a UV light source to fabricate a very small parent structure (see FIG. 6A). do. Compared to UV exposure, where the module is thick or where excellent surface roughness is required, DXRL exposure is more advantageous for producing micromatrix.

The metal electroplating process of the second step ST2 proceeds to an electroplating process using copper, nickel, a nickel alloy, and a metal including one of them, based on the parent structure, depending on the final purpose. That is, a module having a microstructure is manufactured by a copper electroplating, nickel electroplating, or nickel alloy electroplating process. The second step ST2 forms modules having various shapes on the surface of the microstructure in various thicknesses.

The third step ST3 selects modules of various thicknesses having various microstructures, combines and combines the selected modules, and forms a micro mold system with various structures as a whole.

Therefore, the micro mold system according to the embodiment forms a roll shape by combining and combining modules having various set thicknesses, and forms a complicated shape on the surface of the roll shape, thereby continuously forming a large amount of micro structures having various and complicated shapes continuously. Can be.

In order to avoid duplication of explanation, the following describes the structure of the micro mold system and specific examples of the manufacturing method thereof.

2 is a perspective view of a roll-shaped micro mold forming module which is applied to a roll-shaped micro mold system according to an exemplary embodiment of the present invention and manufactured by exposure in a plane direction and metal electroplating.

A mother structure is prepared by attaching polymethyl methacrylate (PMMA), which is a photosensitive material to a metal substrate, selectively exposing the PMMA using an X-ray mask, and then developing it (not shown). After the metal electroplating process is performed to form the metal structure in the empty space of the fabricated parent structure, the remaining parent structure is removed, thereby leaving the modules 101 on the metal substrate 104.

In this way, the module 101 is manufactured by the first and second steps ST1 and ST2, is formed in a cylinder shape with a set thickness t, and has a microstructure 103 on the surface thereof, and has a fitting in the center thereof. Has 102. The microminiature structure 103 is manufactured by exposure to the surface on the cylinder of the set thickness t. The coupler 102 is formed at the center of the module 101 to facilitate the combination and coupling of the modules 101.

3 is a perspective view of a combination of modules forming a microstructure of various shapes on the surface. Referring to FIG. 3, each of the plurality of modules 101 may have various thicknesses t, and each may have a microstructure 103 having a different shape, thereby forming various micro mold systems by various combinations and combinations. have.

For example, the modules 101 may include a first module 201 that forms a triangular microstructure formed on a surface thereof, a second module 202 that forms a quadrangle, and a third module 203 that forms a trapezoidal shape. Include. In addition, the modules may be variously formed, such as a curve not shown.

When at least the first, second, and third modules 201, 202, and 203 are combined, a micro mold system having a complicated shape that is difficult to implement by a general manufacturing technique may be implemented. In addition, the modules 101 can freely modify and set the desired final shape of the mold through various combinations of prefabricated modules.

4 is a perspective view of a process of continuously forming a microstructure by using a roll-shaped micro mold system according to an embodiment of the present invention. Referring to FIG. 4, the micro mold system 301 may be applied to a mass forming technique of a roll-type micro structure, thereby continuously forming a micro structure 304 having a complicated shape.

The micro mold system 301 combines and combines the plurality of modules 302, and is formed in a roll shape as a whole, and in a roll-to-plate manner on a flat plastic sheet 303 (or molten plastic) 304 can be easily molded.

FIG. 5 is a conceptual view of manufacturing a microminiature structure by an X-ray exposure process using a radiation accelerator in the manufacturing method of FIG. 1.

Referring to FIG. 5, the electrons accelerated in the linear accelerator of the emission accelerator emit high energy radiation of various wavelengths in a tangential direction at a predetermined point while rotating the storage ring 401. High energy radiated light is passed through several beamline fixtures 402 and then used in an X-ray exposure process.

An X-ray mask (not shown) is required to selectively irradiate the final high-energy X-ray 403 to a desired area, and such an X-ray mask and photosensitive material are attached to the scanner 404 at a constant speed. Move. Thus, the photosensitive material is exposed to X-rays, and after development, is formed into a micro parent structure.

6A is a perspective view of parent structures of a roll-shaped micro mold forming module manufactured by an X-ray exposure process. Referring to FIG. 6A, as actually manufactured by the manufacturing method of the embodiment, in the X-ray exposure process, the PMMA plate 503 having a thickness of 1 mm is attached to the titanium substrate 504 to be used as a photosensitive material.

That is, FIG. 6A illustrates a PMMA parent structure 501 manufactured through an X-ray exposure process and a development process. After the exposure process, since the PMMA parent structure 501 is used as the parent structure 501 for metal electroplating, the final module has the opposite shape. For example, the parent structure 501 has a corresponding subminiature structure 511 on the outside and a corresponding protrusion 512 on the center.

FIG. 6B is a perspective view of roll-shaped micro mold forming modules manufactured by an electroplating process for the parent structure of FIG. 6A. Referring to FIG. 6B, as actually manufactured by the manufacturing method of the embodiment, the empty structure of the parent structure 501 is filled with copper through an electroplating process, and the parent structure 501 is removed by removing the PMMA plate 503. Modules 505 are formed in positions corresponding to the fields 501.

The fabricated modules 505 have various microstructures 506 formed on the side of the corresponding microstructures 511, and have coupling members 507 formed by the corresponding protrusions 512 at the center thereof.

7A, 7B and 7C are partial perspective views of a roll-shaped micro mold forming module having triangular, square and trapezoidal microstructures on its surface.

7A, 7B, and 7C, which are actually manufactured by the manufacturing method of the embodiment, the modules 601, 602, and 603 have a cylindrical shape through an X-ray exposure and an electroplating process, and have a surface thereof. Illustrate each having triangular, rectangular and trapezoidal microstructures.

FIG. 8A is a perspective view of a roll-shaped micro mold system manufactured by combining / combining modules for forming a micro mold having various microstructures, and FIG. 8B is a partially enlarged view of FIG. 8A.

8A and 8B, as actually manufactured by the manufacturing method of the embodiment, the micro mold system 700 is configured in a roll shape by combining the modules 701 into a desired structure.

To this end, the micro mold system 700 includes a shaft member 702 and a support member 703. The shaft member 702 is inserted into each coupling hole (see 102 in FIG. 3) formed at the center of the plurality of modules 701, and the support member 703 is formed on both sides of the combined and coupled modules 701. 702 is coupled to support the modules 701, thereby forming a stable coupling structure of the shaft member 702 and the module 701.

The shaft member 702 is formed long so that it can be applied to an ultra-small mass forming technique of a roll method. The shaft member 702 and the coupler (not shown) are formed and coupled correspondingly to each other, that is, the shaft member 702 is formed into a cross-sectional square, and the coupler is formed into a rectangular hole, so that the modules on the shaft member 702 701 is prevented from rotating.

That is, the micro mold system 700 forms a roll state with the modules 701, and complexly forms a shape by the micro structures on the surface.

FIG. 9A is a perspective view of a plastic structure prototyped using a fabricated roll-shaped micro mold system, and FIG. 9B is a partial enlarged view of FIG. 9A. 9A and 9B illustrate plastic molded microstructures.

An LDPE structure 801 was formed by performing roll molding on molten low density polyethylene (LDPE). Molten LDPE lowers the viscosity of the plastic to favor molding conditions. LDPE structure 801 has microstructures 802, 803, and 804 on its surface.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited thereto, and various modifications and changes can be made within the scope of the claims and the detailed description of the invention and the accompanying drawings. Naturally, it belongs to the scope of the invention.

101, 302, 505, 601, 602, 603, 701: Module 102, 507: Coupler
103, 304, 802, 803, 804: ultra-small structure 104: metal substrate
201, 202, 203: first, second and third modules 301, 700: micro mold system
303: plastic sheet 402: beamline equipment
403: high energy X-ray 404: scanner
504: titanium substrate 503: PMMA plate
501: parent structure 511: corresponding micro structure
512: corresponding projection 702: shaft member
703: support member 801: LDPE structure
t: thickness

Claims (8)

A first step of fabricating an ultra-small parent structure by an exposure process;
A second step of forming a micro mold forming module by forming a micro structure on the surface of the parent structure by a metal electroplating process; And
A third step of combining and combining the modules to form a roll-shaped micro mold system
Roll-shaped micro mold system manufacturing method comprising a. The method according to claim 1,
The exposure step of the first step,
Deep x-ray lithography (DXRL) process using X-rays of an emission accelerator, and
The roll-shaped micro mold system manufacturing method which is any one of the exposure process which uses UV as a light source. The method according to claim 1,
The metal electroplating process of the second step,
A method of manufacturing a roll-shaped micro mold system, which is any one of copper electroplating, nickel electroplating and nickel alloy electroplating. The method according to claim 1,
The second step,
A method of manufacturing a roll-shaped micro mold system for forming the module having the microstructure on the surface in various thicknesses. The method of claim 4, wherein
In the third step,
Select the modules of varying thickness with different microstructures,
Combining and combining the modules,
Forming the roll-shaped micro mold system into various structures
Method of manufacturing a roll-shaped micro mold system. A roll-shaped micro mold forming module which is formed on a cylinder having a predetermined thickness and has a micro structure on its surface;
A shaft member inserted into a coupler formed at the center of the module; And
Support members coupled to the shaft member at both sides of the combined and coupled modules to support the modules
Roll-shaped micro mold system comprising a. The method of claim 6,
The modules,
Roll-shaped micro mold system having the microstructure on the surface and having a variety of thickness. The method of claim 6,
The micro structure formed on the surface of the module
Roll-shaped micro mold system formed into one of triangular, square and trapezoidal.

Images