TWI419781B - Method for manufacturing mold - Google Patents

Description

Mold manufacturing method

The present invention relates to a mold manufacturing method, and more particularly to a mold manufacturing method for an ultraviolet forming embossing process.

UV forming embossing technology (see Liang Ying-xin, Wang Tai-hong, "A New Technique for Fabrication of Nanodevices-Nanoimprint Lithography", Micronanoelectronic Technology, 2003, Vol. 4-5) is irradiated with ultraviolet light at room temperature. The imprinting technology for curing of polymers is especially suitable for high-volume, reproducible and precise preparation of microstructures. The UV forming embossing technique first manufactures a mold having a microstructure, and then uses the mold to perform an embossing process, and finally performs pattern transfer.

The prior art mold manufacturing method includes the steps of: providing a light transmissive substrate; coating a photoresist layer on a surface of the light transmissive substrate; exposing and developing; etching the substrate to form a microstructure pattern; seeding layer metallization; Electroforming; demolding and removing the seed layer to form a mold.

However, in the manufacturing method, the steps of etching, electroforming, etc. are required to complete the manufacture of the mold, the process is cumbersome, and the production efficiency is low.

In view of this, it is necessary to provide a mold preparation method which is relatively simple and easy to manufacture and has high production efficiency.

Providing a grid plate on a surface of the substrate, the grid plate having a plurality of through holes, the wall surrounding the plurality of through holes being matched with the substrate to form a plurality of molding cavities; using a sub-molded body having a first molding surface and surrounding each of the through holes Forming a small female mold core in each of the molding cavities; removing the grid plate to obtain a mother mold core having the substrate and a plurality of small mothers formed on the substrate and separated from each other a mold core; a mold layer is disposed on the mother mold core, the mold layer covers the surface of the plurality of small mold cores and the surface of the substrate between the two small mold cores; the mold layer is cured, and after curing The mold layer is separated from the master mold to obtain a mold.

Compared with the prior art, the mold manufacturing method of the present invention can complete the manufacture of the mold for the ultraviolet forming imprinting process without etching, electroforming, etc., and the manufacturing process is simple and the production efficiency is improved.

4‧‧‧Small lens mold

30‧‧‧子模仁

301‧‧‧Formed end

303‧‧‧First molding surface

10‧‧‧Substrate

101‧‧‧ first surface

102‧‧‧ second surface

20‧‧‧ grid

201‧‧‧ molding cavity

40‧‧‧Feeding device

50‧‧‧Molden Preform

60‧‧‧Little Mother

601‧‧‧Second molding surface

70‧‧‧Female model

80‧‧‧Mold layer

401‧‧‧ Third molding surface

1 is a flow chart of a method of manufacturing a mold in an embodiment of the present invention.

2 is a schematic view of a substrate and a grid in the embodiment of the present invention.

3 is a schematic view of a neutrino in the embodiment of the present invention.

4 is a schematic view showing the preparation of a small master mold on a substrate by a sub-molded body in the embodiment of the present invention.

Fig. 5 is a schematic view showing a mother mold formed in the embodiment of the present invention.

Figure 6 is a schematic view showing the placement of a mold layer on a master mold in an embodiment of the present invention.

Figure 7 is a schematic illustration of a mold core made in the practice of the present invention.

Please refer to FIG. 1, which is a flow chart of a method for manufacturing a mold according to an embodiment of the present invention. The method comprises the steps of: disposing a grid on a surface of a substrate, the grid having a plurality of through holes, the wall surrounding the plurality of through holes cooperate with the substrate to form a plurality of molding cavities; and using a submolecule having a first molding surface Forming a small female mold core in each of the molding cavities respectively with the wall of each of the through holes; removing the grid plate to obtain a mother mold core having the substrate and a plurality of substrates formed thereon And a small mother mold separated from each other; a mold layer is disposed on the mother mold core, the mold layer covers the surface of the plurality of small mold cores and the surface of the substrate between the two small mold cores; curing the mold The layer is separated from the cured mold layer to obtain a mold.

The mold manufacturing method in the embodiment of the present invention will be described in detail below by taking the micro lens mold 4 as an example.

As shown in FIG. 2, a substrate 10 is provided. The substrate 10 has a first surface 101 and a second surface 102 opposite the first surface 101. In this embodiment, the substrate 10 is a light-transmitting substrate made of quartz. Of course, the substrate 10 can also be a light-transmitting substrate made of other light-transmissive materials such as glass.

A grid 20 having a plurality of through holes is provided. The through holes may be regularly or irregularly distributed on the grid 20. Preferably, in this embodiment, the through holes are distributed in an array on the grid 20 on.

The grid 20 is disposed on the first surface 101 of the substrate 10 such that the grid 20 cooperates with the substrate 10 to form a plurality of molding cavities 201.

As shown in Figure 3, a sub-mold 30 is provided having a cylindrical shaped end 301. The diameter of the forming end 301 matches the diameter of the through hole of the grid 20 so that the forming end 301 can conform to the wall around the through hole in a subsequent process. The forming end 301 has a first forming surface 303. The first molding surface 303 can be used to form a spherical lens or an aspherical lens. In this embodiment, the first molding surface 303 is an aspherical surface that is recessed inward.

As shown in FIG. 4, a mold body pre-form 50 in a viscous fluid state is injected into a molding cavity 201 using a feeding device 40. The mold core preform 50 is made of a photocurable material. In the present embodiment, the mold core preform 50 is made of an epoxy resin. Of course, it can also be made of other photocurable materials such as acrylic resin, polyurethane, and polyoxymethylene resin.

The first molding surface 303 of the mold core 30 is pressed toward the mold preform 50 to form a small mold core 60, and then the small mother mold 60 is irradiated with ultraviolet light from the second surface 102 of the substrate 10 to make the mother The mold core 60 is cured.

The sub-mold 30 is removed, and the above steps are repeated such that a small female mold core 60 is formed in each of the molding cavities 201. The small mold core 60 has a second molding surface 601 that matches the first molding surface 303 of the sub mold core 30. In this embodiment, the second molding surface 601 is an aspherical surface that protrudes outward.

As shown in FIG. 5, the grid 20 is removed to obtain a female mold core 70. The mother mold 70 is composed of a substrate 10 and a plurality of small mold cores 60 which are separated from each other and distributed on the substrate 10.

As shown in FIG. 6, a mold layer 80 is disposed on the female mold core 70. The material of the mold layer 80 is other curable materials such as polydimethyl siloxane or photocurable resin. The mold The layer 80 can be set by a spin coating method, a spray method or a casting method, and the thickness can be designed according to actual needs. In this embodiment, a polydimethyl methoxy oxane having a high viscosity and a viscous fluid state is filled in a gap between the surface of the small mother mold core 60 and the two small female mold cores 60 by a casting method, thereby forming a Mold layer 80.

The mold layer 80 is heat cured. The heat curing can be carried out by hot air convection in the oven, infrared radiation or heat transfer from the thermal pad. In this embodiment, heat conduction using a thermal pad is performed. Of course, if the mold layer 80 is a photocurable resin, the mold layer 80 is cured by a photocuring method.

As shown in FIG. 7, the mold layer 80 is separated from the female mold core 70. The separated mold layer 80 is the minute lens mold 4. The micro lens mold 4 has a plurality of third molding faces 401 matching the second molding faces 601 of the small mold cores 60, that is, the shape of the third molding faces 401 is the same as the shape of the first molding faces 303 of the sub mold cores 30. In this embodiment, the third molding surface 401 is an aspherical surface that is recessed inward.

Of course, the first molding surface 303 of the sub-die 30 can also be an outwardly convex aspheric surface. At this time, the third molding surface 401 of the micro lens mold 4 is correspondingly an outwardly convex aspheric surface.

It can be understood that if the substrate 10 is an opaque substrate made of an opaque material, the material of the mold preform 50 is correspondingly selected as a heat curable material (for example, acrylic resin, polyurethane, and poly The purpose of the present invention can also be achieved by a silicone resin or the like.

It can be understood that the mold preform 50 can be injected into each molding cavity 201 first, and then the first molding surface 303 of the sub mold core 30 is pressed toward the mold preform 50 in a molding cavity 201, thereby forming The small mold core 60 is then irradiated with ultraviolet light from the second surface 102 of the substrate 10 to the small mold core 60 to cure the small mold core 60, and the sub mold core 30 is removed, again The first molding surface 303 of the sub-die 30 is pressed toward the mold preform 50 in the other molding cavity 201 to form another small mold core 60, from the second surface 102 of the substrate 10 to the other small The female mold core 60 irradiates ultraviolet light to cure the other small female mold core 60, removes the sub mold core 30, and reuses the sub mold core 30 so that the mold core preform 50 in each molding cavity 201 becomes a small female mold core. 60, that is, a small master mold 60 is formed in each of the molding cavities 201. Of course, in this method, when a small female mold core 60 is cured, it is necessary to control the ultraviolet light so that the other mold core preform 50 which is not deformed into the small female mold core 60 is not cured.

In summary, the present invention complies with the requirements of the invention patent and submits a patent application according to law. However, the above description is only the preferred embodiment of the present invention, and equivalent modifications or variations made by those skilled in the art will be covered by the following claims.

Claims (7)

A mold manufacturing method comprising the steps of: providing a grid on a surface of a substrate, the grid having a plurality of through holes, the wall surrounding the plurality of through holes being matched with the substrate to form a plurality of molding cavities; using a first molding The mold cores of the face are respectively matched with the wall around each of the through holes to form a small mold core in each of the molding cavities; the plate is removed to obtain a mother mold, the mother mold having the substrate and a plurality of a small mold core on the substrate and separated from each other; a mold layer is disposed on the mother mold core, and the mold layer covers the surface of the plurality of small mold cores and the surface of the substrate between the two small mold cores The mold layer is cured, and the cured mold layer is separated from the mother mold to obtain a mold. The method for manufacturing a mold according to claim 1, wherein a method of forming a small mold core in each of the molding cavities is: injecting a mold pre-form into a molding cavity, the sub-module a molding surface is pressed against the mold preform, and the molded preform is deformed into a small mold core after being pressed, the small mold core is solidified, the mold core is removed, and the mold is repeated, so that each molding is performed. A small female mold is formed in the cavity. The method for manufacturing a mold according to claim 1, wherein a method of forming a small mold core in each of the molding cavities is: injecting a mold pre-form into each of the molding cavities, the sub-module a molding surface is pressed against a mold preform in a molding cavity, and the molded preform is deformed into a small female mold core after being pressed, the small female mold core is solidified, the sub mold core is removed, and the mold core is reused. The small female mold body has a small female mold core formed in each of the molding cavities. The mold manufacturing method according to claim 2, wherein the small mold core is cured by an ultraviolet curing method or a thermal curing method. The method of manufacturing a mold according to the fourth aspect of the invention, wherein the material of the small mold core is an epoxy resin, an acrylic resin, a polyurethane or a polyoxymethylene resin. The method for manufacturing a mold core according to claim 1, wherein the material of the mold layer is polydimethyl siloxane or a photocurable resin. The method of manufacturing a mold according to claim 1, wherein the mold has a second molding surface which is the same as the first molding surface.