WO2002094532A1 - Procede de moulage par injection - Google Patents
Procede de moulage par injection Download PDFInfo
- Publication number
- WO2002094532A1 WO2002094532A1 PCT/JP2002/004869 JP0204869W WO02094532A1 WO 2002094532 A1 WO2002094532 A1 WO 2002094532A1 JP 0204869 W JP0204869 W JP 0204869W WO 02094532 A1 WO02094532 A1 WO 02094532A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mold
- resin
- injection molding
- molding method
- filling
- Prior art date
Links
- 238000001746 injection moulding Methods 0.000 title claims abstract description 54
- 229920005989 resin Polymers 0.000 claims abstract description 130
- 239000011347 resin Substances 0.000 claims abstract description 130
- 238000000034 method Methods 0.000 claims abstract description 74
- 238000000465 moulding Methods 0.000 claims abstract description 37
- 238000002347 injection Methods 0.000 claims description 50
- 239000007924 injection Substances 0.000 claims description 50
- 239000012530 fluid Substances 0.000 claims description 43
- 238000003825 pressing Methods 0.000 claims description 34
- 239000000463 material Substances 0.000 claims description 29
- 230000008569 process Effects 0.000 claims description 29
- 239000000758 substrate Substances 0.000 claims description 26
- 229920005992 thermoplastic resin Polymers 0.000 claims description 25
- 230000009477 glass transition Effects 0.000 claims description 19
- 238000005429 filling process Methods 0.000 claims description 4
- 230000003287 optical effect Effects 0.000 abstract description 26
- 238000004519 manufacturing process Methods 0.000 abstract description 10
- 239000000047 product Substances 0.000 description 53
- 238000001816 cooling Methods 0.000 description 29
- 238000010438 heat treatment Methods 0.000 description 24
- 239000007789 gas Substances 0.000 description 14
- 238000010586 diagram Methods 0.000 description 13
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 12
- 238000007789 sealing Methods 0.000 description 11
- 239000010410 layer Substances 0.000 description 9
- 230000007246 mechanism Effects 0.000 description 9
- 229910002092 carbon dioxide Inorganic materials 0.000 description 7
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- 238000007711 solidification Methods 0.000 description 6
- 230000008023 solidification Effects 0.000 description 6
- 241001634822 Biston Species 0.000 description 5
- FFGPTBGBLSHEPO-UHFFFAOYSA-N carbamazepine Chemical compound C1=CC2=CC=CC=C2N(C(=O)N)C2=CC=CC=C21 FFGPTBGBLSHEPO-UHFFFAOYSA-N 0.000 description 5
- 239000000498 cooling water Substances 0.000 description 5
- 238000005259 measurement Methods 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 4
- 239000008188 pellet Substances 0.000 description 4
- 239000004417 polycarbonate Substances 0.000 description 4
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
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- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 2
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- 229920000098 polyolefin Polymers 0.000 description 2
- 230000003362 replicative effect Effects 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920002020 Microcellular plastic Polymers 0.000 description 1
- 239000004697 Polyetherimide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 230000005856 abnormality Effects 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
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- 210000000497 foam cell Anatomy 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
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- 239000000155 melt Substances 0.000 description 1
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- 150000002739 metals Chemical class 0.000 description 1
- UIAGMCDKSXEBJQ-UHFFFAOYSA-N nimodipine Chemical compound COCCOC(=O)C1=C(C)NC(C)=C(C(=O)OC(C)C)C1C1=CC=CC([N+]([O-])=O)=C1 UIAGMCDKSXEBJQ-UHFFFAOYSA-N 0.000 description 1
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920005668 polycarbonate resin Polymers 0.000 description 1
- 239000004431 polycarbonate resin Substances 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 229920006380 polyphenylene oxide Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
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- 230000000630 rising effect Effects 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 229910021332 silicide Inorganic materials 0.000 description 1
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000009757 thermoplastic moulding Methods 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/04—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles using movable moulds
- B29C43/06—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles using movable moulds continuously movable in one direction, e.g. mounted on chains, belts
- B29C43/08—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles using movable moulds continuously movable in one direction, e.g. mounted on chains, belts with circular movement, e.g. mounted on rolls, turntables
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
- B29C2043/023—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves
- B29C2043/025—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves forming a microstructure, i.e. fine patterning
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
- B29C2043/3433—Feeding the material to the mould or the compression means using dispensing heads, e.g. extruders, placed over or apart from the moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
- B29C2043/3488—Feeding the material to the mould or the compression means uniformly distributed into the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C2043/3676—Moulds for making articles of definite length, i.e. discrete articles moulds mounted on rotating supporting constuctions
- B29C2043/3689—Moulds for making articles of definite length, i.e. discrete articles moulds mounted on rotating supporting constuctions on a support table, e.g. flat disk-like tables having moulds on the periphery
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/34—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station
- B29C33/36—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station continuously movable in one direction, e.g. in a closed circuit
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
- B29C33/424—Moulding surfaces provided with means for marking or patterning
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/14—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2017/00—Carriers for sound or information
- B29L2017/001—Carriers of records containing fine grooves or impressions, e.g. disc records for needle playback, cylinder records
- B29L2017/003—Records or discs
Definitions
- the present invention relates to an injection molding method having excellent transferability, optical properties, and productivity.
- thermoplastics In injection molding of thermoplastics, a mold is mounted on an injection molding machine, and the resin that is heated and melted is injected into a mold whose temperature is controlled below the glass transition temperature of the resin material used. The repetitive process of pressurizing with mold clamping pressure and taking out the product after cooling and solidifying is performed. In products such as optical discs that require precise transfer of molds in the order of submicrons, it is necessary to control not only transfer but also optical and mechanical properties by such a molding method.
- FIGS. 14 to 17 show a conventional molding method for an optical disk such as a CD or DVD.
- the cavity (37) of the space to be filled with resin is fixed by the fixed dies (32) and the fixed dies (33) mounted on the movable platen (33) of the molding machine, respectively. It is formed by closing both the movable mold (30) and the movable mold (31).
- polycarbonate having bisphenol A as a monomer is used as the resin of the optical disc, and the glass transition temperature (Tg) is adjusted to about 130 to 150 from the molecular weight and the like.
- a temperature control circuit (not shown) is provided in both dies, and temperature control water of about 80 to 130 ° C, which is lower than the glass transition temperature of the resin, is constantly flown.
- the resin filling process is performed by the resin melted in a plasticizing cylinder (not shown) in the molding machine, and the resin is brought into contact with the stationary mold (30) from the nozzle tip (34). It takes place via a pool (36).
- the thickness of optical discs such as DVD has become 0.6 mm, which is smaller than the 1.2 mm thickness of CDs, and it has become difficult to fill the cavity (37).
- the temperature is set higher than the product thickness, and the cylinder temperature, that is, the resin temperature, is set higher than 300 to 340 ° C for a CD or the like, and is set to 360 to 390 ° C to reduce the viscosity as much as possible.
- the molten resin fills the cavity while solidifying while contacting the mold wall surface, the solidified layer is cooled and grows as filling proceeds. For this reason, it is necessary to increase the injection pressure, which is the pressure of the motor / cylinder, etc., for moving the screw forward. Therefore, the internal pressure of the resin generated during injection filling increases.
- the flow end of the resin (42) often does not reach the mold member (43) that forms the outer diameter of the product, which is the end of the cavity.
- the cavity thickness T at the time of filling is larger than the product thickness t at the time of filling and filling is performed, and as described later, the cavity thickness is reduced by compression by mold clamping after filling.
- a solidified layer is formed between the mold wall surface and the flowing resin during filling, and shear stress is generated, which causes an increase in birefringence.
- the growth of the solidified layer that is, the skin layer is different between the inner circumference and the outer circumference, the difference in the birefringence between the inside and the outside tends to increase.
- the photoelastic constant of the resin material has been reduced, it has disadvantages such as higher cost and lower rigidity.
- the resin viscosity increases as it goes to the outer periphery.
- transferability deteriorates, and it is difficult to obtain uniform transfer inside and outside.
- the resin material used is largely restricted in order to maintain fluidity.
- T g will generally increase, and sufficient filling will not be possible. Therefore, there are great restrictions on reducing the product thickness.
- the solidified layer on the transfer surface that is in contact with the mold has a detrimental effect, and it is necessary to increase the mold clamping force in order to obtain sufficient transferability, thereby increasing the damage of the stamper (7), The generation of internal stress was unavoidable.
- the eccentricity of the cut punch (38) with respect to the stamper (7) after punching must be controlled at least within 30 ⁇ m.
- the temperature distribution of the fixed and movable molds is deteriorated due to the increase of the height, and it becomes difficult to maintain the alignment accuracy.
- the shape of the pre-pit group is likely to be asymmetric on the signal surface of the substrate, as in the details of the part, especially on the outer periphery. This is considered to be because the amount of shrinkage on the inner circumference side increases toward the outer circumference, and the linear expansion coefficient is smaller than that of the resin material and the shrinkage amount is smaller because the stamper is made of a metal material.
- the stamper suffers large damage due to the internal pressure of the resin and the mold clamping force. It is difficult considering the nature. Furthermore, the solidification of the outer periphery is fast and the difference in cooling rate between the inside and outside is large. Even if the amount of deformation of the pre-group is as small as about 10% or less with respect to the group depth d of 60 to 250 nm, a narrow track pitch, a shorter laser wavelength, and a higher In recent years, with the progress of NA and the spot diameter for recording and reproduction on the substrate has become smaller, it may become a group noise, which is becoming a major problem.
- the above-mentioned sink marks are large in the core layer inside the product. As shown, they tend to be trumpet-shaped and wedge-shaped. This change in shape at the outer periphery may be called a ski jump. '
- the thickness of the solidified layer is inevitable during filling, and the viscosity and cooling rate at the filling start position and the flow end position are different. Stricter precision and requirements for transfer and optical properties, etc., had limitations, and material constraints were severe, making it difficult to obtain high-quality products.
- the mold temperature is increased by filling and cooling in the same mold to obtain high transferability, the cooling time must be extended in order to obtain good mechanical characteristics. There is also a problem that efficiency is not high.
- thermoplastic resin raises the temperature of the material and makes use of the properties of the non-Newtonian fluid to reduce the viscosity by generating heat by shearing by high-speed injection or the like.
- the mold After filling into the mold, it comes into contact with the mold whose temperature is controlled at a very low temperature of 100 ° C or more, which is higher than the resin temperature. This is because there is a limit to the low viscosity even if a temporarily inhibited the like. also, for dissolving the co 2 from Furofuro cement during high-speed filling, undissolved in the microstructure occurs.
- the second 7 Figure, Fig. 28 shows the state in which the resin material (10 9) is flowed on the surface of the transfer target structure (103) such as a stamper held in the support mold (110), and the resin material is placed in the mold.
- (1 1 1) shows the state after press filling.
- the filling ratio of the resin in the structure (1 1 2) to be transferred is defined as the aspect ratio, which is defined as the ratio (DZW) between the maximum width W and the maximum depth D of the entrance.
- the present invention has been made to solve the above-mentioned problems in the conventional injection molding method, and has a precise transfer property capable of accurately transferring an ultra-fine structure that cannot be satisfactorily transferred by the conventional molding method. It is an object of the present invention to provide an injection molding method capable of improving production efficiency, such as obtaining optical characteristics and mechanical characteristics, and replicating a large number of replicas. Disclosure of the invention
- the present invention relates to an injection molding method for obtaining a molded product, wherein a mold for forming a cavity is composed of at least two or more members, and the mold is filled with a molten resin.
- One of the members constituting the mold moves on a stage that is divided into at least three or more steps of a filling step, a pressing step, and a molded article removing step, and the one part is closed in the filling step. It is an object of the present invention to provide an injection molding method characterized by forming a molded product in a press step after filling a molten resin into a cavity.
- a molding method in which a resin plasticized and melted by a screw is filled in a mold and solidified to obtain a molded product is defined as injection molding.
- the molten resin is not filled in the closed mold, a solidified layer on the mold wall surface generated at the time of flowing hardly occurs, and the molten state of the resin surface is uniform on the surface that does not touch the mold. Since the resin temperature can be maintained, the resin temperature at the time of filling can be lowered, and high transferability can be obtained even when a resin having high rigidity and low fluidity is used. Even if the filling is advanced, the internal pressure of the resin does not increase due to the solidification of the resin, so there is no need to increase the injection pressure to advance the screw.
- the injection molding method of the present invention is characterized in that the unblocked cavity is filled with a molten resin in a vacuum.
- the movable mold By filling in a vacuum, voids and bubbles do not appear on the resin surface after filling due to gas or air generated from inside the resin. Then, after filling, the movable mold is moved to another cooling stage and then press-cooled to obtain the product shape, so that the resin can be uniformly transferred in a state where the resin viscosity on the surface is low, and the conventional molding can be performed.
- the transfer can be performed with a press pressure that is significantly lower than the mold clamping pressure necessary for obtaining the transferability in the above. Therefore, a mold member such as a stamper having information to be transferred can be produced without being limited to a highly durable metal material.
- the injection molding method of the present invention since the internal stress generated at the time of pressing is small, the oblique incidence birefringence is reduced even if a resin material having a large photoelastic constant and easily increasing the stress is used. Also, since the temperature of the resin to be injected can be lowered, the cooling time can be shortened by setting the temperature of the cooling stage lower than the stage temperature of the injection process, thereby improving production efficiency.
- one of the members constituting the mold moves on a stage divided into at least three or more steps of a filling step, a pressing step, and a molded article removing step,
- a molten resin is filled in a cavity in which a member is not closed, and a supercritical fluid of co 2 gas is permeated into the molten resin under pressure, and then a molded product is formed in a pressing step.
- the molten resin contains a supercritical fluid of CO 2 gas
- the properties of the resin as a viscous material inherent to the resin are modified by the permeability of the supercritical fluid, and the coatability of fine irregularities is improved. Transfer becomes possible.
- the fluid maintains the supercritical state until the resin material is completely solidified. Foaming by gasification is avoided.
- the supercritical fluid is gasified by releasing the mold pressure, and the solidified thermoplastic resin is molded from the mold by the gas pressure. It is characterized in that it is released from the mold.
- the supercritical fluid is gasified by releasing the mold pressure, and the resin molded product is released from the ultra-fine structure of the mold by the gas pressure.
- a replica that accurately transfers the shape of a microstructure can be released without impairing the shape accuracy.
- the one member is moved on a stage heated to (Tg ⁇ 20) ° C. or more (Tg: glass transition temperature) of a resin material used in an injection step.
- Tg glass transition temperature
- the minimum mold thickness from both heating stages to the cavity is preferably 10 mm or less. This suppresses cooling of the mold contact surface during injection. In this way, the cooling of the product can be promoted at the time of pressing, and the mass production efficiency can be improved without deteriorating the product quality.
- the shape of the nozzle tip in the injection step can be arbitrarily changed according to the product shape. Further, it is preferable that the shape of the nozzle tip forms a shape close to the cavity together with the moving die. As a result, even when the product shape is complicated or the shape is large, the resin surface temperature after filling can be made uniform over the entire surface, so that uniform and good transfer can be obtained.
- the filling temperature of the thermoplastic resin into the mold and the initial stage of pressing are set to a mold temperature equal to or higher than the glass transition temperature Tg of the thermoplastic resin, and the mold temperature is set to Tg during the pressing. It is preferable to lower and solidify.
- FIG. 1 is an overall configuration diagram of an injection molding machine of the present invention as viewed from above.
- FIG. 2 is a cross-sectional structural view of a main part of an injection process unit in the injection molding machine of the present invention, and is a diagram schematically showing a state of the start of plasticization.
- FIG. 3 is a cross-sectional structural view of a main part of an injection process unit in the injection molding machine of the present invention, schematically showing a state at the time of completion of plasticization.
- FIG. 4 is a cross-sectional structural view of a main part of an injection process unit in the injection molding machine of the present invention, and is a diagram schematically showing a state at the time of injection filling.
- FIG. 5 is a cross-sectional structure of a main part of a press process part in the injection molding machine of the present invention.
- FIG. 3 is a diagram schematically illustrating a state before pressing.
- FIG. 6 is a cross-sectional view of a main part of a press process section in the injection molding machine of the present invention, and is a diagram schematically showing a state at the time of pressing and a state at the time of transfer with a stamper.
- FIG. 7 is a cross-sectional view of a main part of a press process part in the injection molding machine of the present invention, schematically showing a state when the press is opened.
- FIG. 8 is a schematic cross-sectional view of a main part of a take-out step in the injection molding machine of the present invention, schematically showing a state at the time of take-out and a transfer state of the substrate surface.
- FIG. 9 is a sectional view of a main part of a nozzle tip portion in the injection molding machine of the present invention, and is a diagram schematically showing a state at the time of plasticization measurement.
- FIG. 10 is a cross-sectional view of a main part of a nozzle tip portion in the injection molding machine of the present invention, schematically showing a state at the time of injection filling.
- FIG. 11 is a diagram showing a time chart of an injection molding cycle in the present embodiment.
- FIG. 12 shows the results of measuring the vertical incidence retardation of the optical disk substrate in the present example. .
- FIG. 13 shows the results of measuring the cross-sectional birefringence of the optical disk substrate in this example.
- FIG. 14 is a sectional structural view of a main part of a conventional injection molding machine, showing a state before injection.
- FIG. 15 is a sectional view of a main part of a conventional injection molding machine, showing a state at the time of injection.
- FIG. 16 is a cross-sectional structural view of a main part of a conventional injection molding machine, showing a state at the time of mold clamping and a state of transfer with a stamper.
- FIG. 17 is a cross-sectional structural view of a main part of a conventional injection molding machine
- FIG. 4 is a diagram schematically illustrating a state at the time and a transfer state of a substrate surface.
- FIG. 18 is a diagram showing a time chart of an injection molding cycle in a comparative example.
- FIG. 19 shows the result of measuring the vertical incidence retardation of the molded substrate in the comparative example.
- FIG. 20 shows the results of measuring the cross-sectional birefringence of the optical disk substrate in the comparative example.
- FIG. 21 is an explanatory view showing a filling step of molding using a thermoplastic resin in the present invention.
- FIG. 22 is an explanatory view showing a filling step of molding using a thermoplastic resin in the present invention.
- FIG. 23 is an explanatory view showing a pressing step of molding using a thermoplastic resin in the present invention.
- FIG. 24 is an explanatory view showing a pressing step of molding using a thermoplastic resin in the present invention.
- FIG. 25 is an explanatory view showing a pressing step of molding using a thermoplastic resin in the present invention.
- FIG. 26 is an explanatory diagram showing a pressing step of molding using a thermoplastic resin in the present invention.
- FIG. 27 is an explanatory view showing the formation of a microstructure.
- FIG. 28 is an explanatory view showing the formation of a microstructure.
- FIG. 29 is an explanatory view showing the formation of a microstructure.
- FIG. 30 is an explanatory diagram showing a state after the release of the microstructure.
- the resin used in the injection molding method of the present invention is a resin which has a Any resin may be used as long as it changes the solidification state reversibly, and the type thereof is not limited, but a thermoplastic resin is preferably used. ⁇
- thermoplastic resin examples include polyethylene, polystyrene, polyacetanol, polycarbonate, polyphenylene oxide, polymethinole pentene, polyether imide, ABS resin, polymethyl methacrylate, and amorphous polyolefin. .
- a resin having excellent transparency is desirable, and particularly, polyacrylonitrile, ponates, polymethyl methacrylate, amorphous polyolefin and the like are preferable.
- FIG. 1 is a diagram of an injection molding apparatus according to the present invention as viewed from above, and FIGS. 2 to 8 are schematic cross-sectional views of respective process parts of the apparatus.
- FIGS. 2 to 4 show the process from plasticization to filling in the injection step A, and FIGS. 5 to 7 are schematic views of the press step C before and after the press is opened. .
- FIG. 8 illustrates the state of product removal in the removal step C.
- the movable mold (3) rotates and moves each stage around a rotating shaft (6) in a vacuum furnace (1).
- the plasticizing device (10) applies injection pressure from the cylinder (18) to the moving mold (3) on the heating plate (8) to perform injection filling of the molten resin.
- the present invention In vacuum furnaces, vacuum is applied to prevent defoaming by taking in oxygen and the like in the atmosphere from the surface of the molten resin.However, if the vacuum is set too high, low-boiling components evaporate from inside the resin and foam inside. for thus, it is desirable that degree of vacuum in the range of 1 X 1 0- 2 P a ⁇ l X 1 0 3 P a.
- the movable mold is moved to the heating plate (9) in the press cooling step B, and is pressed by the press mechanism (13) provided at the top to obtain the shape accuracy of the product and to be cooled. In this way, the moving mold is brought into close contact with the temperature-controlled heating plates (8) and (9) in the injection step and the press cooling step, respectively.
- the temperature of the heating plate is arbitrary, but in the injection step A, it is higher than (T g-20) ° C for the glass transition temperature of the resin, and in the press cooling step B, it is higher than the glass transition temperature of the resin (T g +100) It is desirable to keep the temperature below ° C. It is also possible to improve production efficiency by providing a stage for heating the mold before the injection process, providing multiple stages for the press and cooling processes, and changing the temperature setting of each stage. it can.
- the moving die (3) moves to the product removal process C, and the removal machine (14) removes the product from the vacuum furnace (1) after transferring it to the small vacuum furnace (17).
- the machine (15) enters the small vacuum furnace (17) through the shutter (16), and after being delivered from the unloader (14), the product is taken out to the atmosphere.
- the moving mold (3) from which the product has been removed moves to the injection process A again. By repeating this process, continuous production becomes possible.
- FIGS. 2 to 8 are schematic sectional views.
- the screw (21) is rotated by the drive of a motor (not shown) in the plasticizing device (10), so that the resin pellet (1 1) is removed from the drying hopper (11). 2) Supply starts.
- This is the same mechanism as the conventional molding device. Movement in the present embodiment
- the mold (3) has a pin (4) at the center of the mold to form the inner diameter of the optical disk, but the shape of the movable mold can be changed depending on the product shape.
- a transfer target such as a stamper (7) can be provided.
- the cavity of the moving mold (3) is not closed, and the molten resin is filled in this state, so that a solidified layer on the mold wall surface generated at the time of flowing hardly occurs. Furthermore, in order to improve the heat exchange rate of the moving mold (3), it is desirable to use a material with high thermal conductivity and to reduce the thickness H as much as possible. Specifically, the thermal conductivity 20 w / ⁇ ⁇ k ( It is desirable that the thickness H should be 15 mm or less for the material of 200 ° C or higher.
- the mechanical shutter (5) is used to prevent the resin internal pressure at the tip of the screw from rising during plasticization measurement and resin leakage from the nozzle tip (2).
- the mechanism for suppressing resin leakage is optional. As shown in Fig. 3, when the weighing is completed, the screw (2 1) is retracted to the weighing position and melts into the area (2 2) in the heating cylinder (20) in front of the screw, as in the conventional molding method. The resin is weighed.
- the gas is exhausted from the vacuum hole (19) located behind the hopper (11).
- the mechanical shutter (5) at the nozzle tip (2) is opened, and at the same time, the screw (21) is inserted into the cylinder (18) located at the rear of the plasticizer.
- the molten resin (2 3) is filled on the movable mold (3) by moving forward by the pressure of (1).
- the shape of the nozzle tip (2) can be optimized according to the shape of the mold. A resin in a molten state close to the shape is formed.
- FIG. 9 a sealing piece (50) is inserted into the tip of the nozzle (2).
- the internal pressure of the resin rises, so pressure is applied in the downward direction in the figure, and the sealing piece (50) drops downward, bringing the nozzle tip (2) into contact with the sealing piece (50).
- Molten resin does not leak from the nozzle because it is closed by the seal piece receiving surface (51).
- the nozzle tip (50) is inserted into the tip of the nozzle (2).
- the filling resin (2 3) keeps the molten state, it becomes closer to the final cavity shape by the nozzle tip (2) and the moving mold (3).
- the movable mold (3) filled with the obtained molten resin is transferred to the heating plate (9) in the press cooling step B.
- at least one or more dies that form cavities with the moving dies are mounted on the press piston (26).
- a stamper on which a pre-group, which is minute information, is engraved on a press die (24).
- the configuration of the mold is optional depending on the product form.
- the material of the stamper is arbitrary, and quartz glass or the like can be used in addition to metal.
- the temperature of the press mold (24) is directly or indirectly controlled by an arbitrary method. In the present embodiment, the temperature is directly controlled by a temperature control circuit (25) through which cooling water flows. As shown in Fig. 6, the press die (24) is clamped with the moving die (3) via the force P of the press piston (26) to form a cavity (37).
- the press die (2, 4) and the pre-spicetone (26) are made independent, and at the same time, the temperature control during each press is changed by using a plurality of press steps.
- the press die like the moving die, is thinned to improve the heat exchange rate, the press die and press biston are set to high temperatures during the initial press, and the temperature of the press biston is reduced after transfer to reduce the press die again.
- the cooling time can be shortened by adhering to the mold and rapidly cooling the press mold. In this case, a large number of press dies are required like the movable dies.
- the centering method of the movable mold (3) and the pre-spicetone (26) is arbitrary, but in the present embodiment, the guide rings (28a) and (28b) provided in a donut shape are attached to each other. Are performed by fitting each other.
- the product (29) and the moving mold (.3) are moved to the unloading step C.
- the method of taking out the product is optional, but in this embodiment, as shown in Fig. 8, first the take-out machine (14) and the suction cup (14A) attached to it come into close contact with the molded product (29). Then, raise the degree of vacuum in the unloader (14) from the vacuum furnace (1), and transfer the molded article (29) into the small vacuum furnace (17). Then, while the small vacuum furnace (17) and the shutter (16) for shutting off the atmosphere are momentarily opened, the take-out machine (15) enters the small vacuum furnace (17) and the take-out machine (17). 14) Receive the molded article (29) from the air and take it out to the atmosphere.
- Example 1 Using the injection molding apparatus shown in FIGS. 2 to 8 in the present invention, a disk-shaped optical disc substrate having an inner diameter of ⁇ 8 mm, an outer diameter of ⁇ 50 ⁇ , and a thickness of 0.4 mm was produced. A spiral pre-group with a track pitch of 0.5m, a groove width of 0.25 ⁇ m, and a groove depth of 70nm is provided on the stamper (7) in the range of inner diameter ⁇ 12mm to outer diameter ⁇ 48mm. Was.
- the thickness H of the movable mold (3) is desirably 15 mm or less, and the force S is desirably set to 10 mm in this embodiment.
- the thermal conductivity of the mold is desirably 20 w / m'k (200 ° C) or more, but in this embodiment, 21.5 w / m-k (200 ° C) HPM38 manufactured by Kinzoku Co. was used.
- the degree of vacuum in the vacuum furnace (1) is desirably in a range capable of suppressing the molten resin from taking in air from the surface and foaming, and suppressing the low-boiling material from the resin from volatilizing and foaming.
- the range of X 10 — 2 to 1 X 10 3 Pa is desirable, but in this embodiment, a vacuum is maintained at 0.1 Pa to 1 Pa using a rotary pump and a mechanical booster pump.
- the molten resin to be filled is arbitrary, but AD5503 (glass transition temperature (Tg): 143 ° C) manufactured by Teijin Chemicals Ltd., which is a polycarbonate resin containing bisphenol A as a monomer, was used.
- the heating temperature of the heater in the plasticizing device (10) is arbitrary, but in the present example, a band heater was used to control the maximum at 300 ° C, and the nozzle tip (2) was controlled to 260 ° C.
- the temperature of the heating plate (8) in the injection process was 250 ° C.
- the surface temperature of the moving mold (3) immediately before filling was 150 ° C.
- the shape of the nozzle tip is designed so that the discharge nozzle has a ring shape and the resin spreads like a donut by injection.
- Injection filling is performed with the nozzle end (17) closed with the mechanical shutter (5), plasticization measurement is performed as shown in Fig. 3, and then the shutter is opened and the screw (2) is opened as shown in Fig. 4.
- the moving mold (3) was transferred onto the heating stage (9) below the press mold (24) equipped with the stamper (7) made of Ni described above.
- the method of attaching the stamper (7) is arbitrary, but in this embodiment, both inside and outside were performed by air vacuum (not shown).
- the heating stay (9) was controlled at 40 ° C with cooling water (not shown).
- the press die (24) is connected to the press piston (26) and is provided with a temperature control circuit (25) through which cooling water flows.
- the mold material and thickness are arbitrary, but the thickness from the press piston mounting position to the stamper was set to 20 mm using HPM 38 manufactured by Hitachi Metals. The distance from the stamper installation surface to the cooling temperature control circuit was 10 mm.
- the drive source of the press biston is arbitrary, and a hydraulic cylinder, an electric motor, an air cylinder, or the like can be used. In this embodiment, an air cylinder was used.
- the cooling water (25) for the press die (24) was controlled at 100 ° C.
- Pressing is performed as shown in Fig. 6, and the outer ring (28b) that regulates the outer diameter of the product in the moving die and the outer ring (28a) of the press die (24) are fitted together. Alignment was performed. The clearance between both outer rings was adjusted to obtain the optimum alignment accuracy by taking into account the temperature difference, that is, the difference in thermal expansion during pressing.
- the pressing force P and the pressing time are arbitrary, but in the present embodiment, the pressing force was applied with a pressing force P of 80.0 kgf for 2 seconds. With this press, the molten resin was filled up to the end of the cavity and transferred to the outer periphery as shown in detail in the section.
- the stamper (7) and the product (29) are released by raising the press piston (26) and press die (24).
- the method of releasing the stamper (7) from the product (29) is optional.
- nitrogen which is an inert gas, is supplied at a flow rate of 51 / min. From a ring-shaped slit provided on the inner periphery of the stamper. It flowed for 0.1 second and was released in 0.3 second. A gas inlet may be provided on the outer periphery, or the gas may be cooled.
- the method of taking out the product (29) from the injection molding machine is arbitrary, but in the present example, the procedure was as follows.
- the movable mold (3) is moved to the removal process, and as shown in Fig. 8, the molded product (29) is released from the movable mold (3) by the suction cup (14A) of the removal machine (14). Transfer to small vacuum furnace (1.7).
- the degree of vacuum in the small vacuum furnace (17) is arbitrary as long as it does not adversely affect the degree of vacuum in the filling step or the pressing step. In this embodiment, the degree of vacuum is controlled to 10 to 50 Pa. did.
- the unloader (15) and the suction cup (15A) penetrate into the vacuum furnace (17) and remove the molded product (29). ), Was retreated to the atmosphere, and the product was removed from the vacuum furnace (17).
- the opening time of the shirt was set to 0.5 seconds.
- FIG. 11 A time chart for each step is shown in FIG. As shown in Fig. 11, a high cycle has been achieved by adjusting the cycle of each process and performing efficient heat exchange between heating and cooling.
- the groove depth was 99% of that of the stamper, and the shape maintained the symmetry as shown in the details of the mouth. I was No abnormalities such as air bubbles and flow marks were observed in the substrate.
- the eccentricity of the group outer diameter with respect to the inner diameter was measured with a tool microscope, it was ⁇ ⁇ ⁇ ( ⁇ - ⁇ ), and it was found that a low eccentric substrate could be manufactured.
- the thickness variation on the entire surface was measured with a micrometer, it was within 2 ⁇ , No ski jumps occurred.
- Fig. 12 shows the measurement results of double pass retardation. It can be seen that the entire surface was within 10 nm and almost no birefringence occurred.
- the Rita one Deshiyon, an optical phase difference, Ri indicator der to detect 'quantify the magnitude of the birefringence
- R (N -! N 2) represented by t.
- N 2 is the circumferential main refractive index in the disk plane
- t is the thickness of the substrate.
- the birefringence is represented by the principal stress difference (Ni-Nj) in the radial direction and the circumferential direction inside the disc.
- the conventional molding method uses a thin optical disk having a thickness of 0.6 mm or less. It was difficult to reduce the birefringence in the vicinity of the inner diameter of the substrate, and the increase in the birefringence of the inner periphery after the high temperature environment was inevitable. However, it was found that the retardation of the product of the present invention after 4 hours beta at a high temperature of 80 ° C hardly changed as shown in FIG.
- FIG. 13 shows the results of measuring the cross section (vertical) birefringence (N x -N z) of the substrate of the present invention which is correlated with the residual stress.
- the cross-sectional birefringence is the difference between the in-plane principal refractive index ( ⁇ or N 2 ) and the principal refractive index N z in the thickness direction, and is described in the Journal of Polymers, Vol. 47, No6 (1990).
- Nx-Nz in the present invention is 2E-04 or less, which is a value that cannot be achieved by the molding method of the conventional molding method. This value is equivalent to a resin material with a small photoelastic constant C. From this result, it was found that the substrate according to the present invention had remarkably small residual stress.
- the same injection molding machine as in Example 1 was used and injection molding was performed in the same manner.
- the temperature of the heater (20) at the nozzle tip was controlled at 250 ° C.
- the temperature of the heating plate (8) is 250. C
- the nozzle is moved in the direction of the arrow in FIG. 10 and the tip (52) of the sealing piece (50) is brought into contact with the inner diameter pin (4) of the moving mold (3).
- the sealing piece (50) in the nozzle was pushed up, and the molten resin (23) was filled into the mold through the resin flow groove (53) on the outer periphery of the sealing piece (50).
- the fluid resin (23) filled on the moving mold (3) was close to the final product shape, and that the transfer surface (54) of the stamper could maintain the flatness.
- the pressing force P in FIG. 6 was set to 400 kgf, which is lower than that in Example 1, because the shape accuracy was at a certain level before pressing.
- FIG. 13 shows the result of measuring the cross-sectional birefringence in the same manner as in Example 1.
- the internal residual stress was able to be reduced as compared with Example 1. This is probably because the stress generated during pressing was reduced.
- Optical disks were manufactured using the same resin as in Example 1 using the conventional molding method shown in FIGS. 1.4 to 17.
- the injection molding machine used was SD35E manufactured by Sumitomo Heavy Industries.
- the temperature set in the temperature control circuit of the fixed die (30) and the movable die (31) is set at 120 ° C, respectively, and the temperature control circuit of the cut punch (38) ⁇ spool (36) is used.
- the filling resin temperature (cylinder heating cylinder temperature) was set to a maximum of 380 ° C, and the filling time was set to 0.04 seconds.
- FIG. 18 shows a time chart of plasticization and mold clamping. Immediately after filling, a mold clamping force of 15 tons was generated for 0.2 seconds to drive the cut punch (38) at the same time as the compression transfer, as shown in Fig. 16, to punch out the inner diameter. After that, the mold clamping force was reduced to 8 tons and held for 2.9 seconds, and then the mold opening product was taken out in 0.4 seconds.
- the transferability of the substrate in this comparative example was measured using AFM. As a result, the transfer rate at the group depth was 98%, but the deformation was slightly observed as shown in Fig. 17 in detail.
- the eccentricity of the signal outer diameter with respect to the substrate inner diameter was 30 / z m (P-P).
- the product thickness was measured, the product showed a variation of 5 ⁇ m from the product outside diameter of 50 mm to an outside diameter of ⁇ 48 mm, which was 2 mm inside. As a result, it was found that a ski jump occurred as shown in part A of FIG. '
- the normal incidence retardation and the cross-sectional birefringence of the optical disk substrate in this comparative example were measured in the same manner as in the example.
- the results are shown in Fig. 19 and Fig. 20.
- the normal incidence retardation is controlled to be 20 nm after molding, which is good. It can be seen that the amount is large.
- FIG. 20 shows that the cross-sectional birefringence is much larger than the value in the present invention.
- the post-baking retardation is performed by the invention of the present inventor by using a method such as changing the cooling efficiency of the mold temperature control circuit between the inner and outer peripheries to reduce the viscosity difference.
- a method such as changing the cooling efficiency of the mold temperature control circuit between the inner and outer peripheries to reduce the viscosity difference.
- it can be controlled up to about ⁇ 30 nm, but it was difficult to reduce the cross-sectional birefringence to 4.0 E-04 or less because the properties of the resin used were large.
- FIG. 21 to Fig. 26 schematically show the molding method when a polycarbonate having a glass transition temperature of 140 ° C is used as a thermoplastic resin material and a supercritical fluid of CO 2 gas is contained in the polycarbonate. This is shown in FIG. Fig. 21 to Fig. 22 show the filling process of the molten resin.
- the moving die (101) equipped with the stamper (103) on which the fine structure is formed is a moving mold.
- the movable mold (101) moves on each step together with the table.
- the microstructure of the stamper (103) has a depth D O. 6 ⁇ l, a width W of 0.15 m and a concave pattern with an aspect ratio of 4 as shown in Fig. 28.
- the structure of a line space with a high aspect ratio that is continuous at 0 and 2 ⁇ m is formed of Ni, and the inner wall of the moving mold has a disk-shaped cavity with a diameter of 50 mm. It was formed.
- This transfer mold is heated to at least the glass transition temperature Tg of the thermoplastic resin, and the heating method is direct or indirect, such as ultrasonic induction heating, heat transfer heating, temperature control solvent heating, heating with a halogen lamp, etc. Any method can be used as long as the method is used for heating.
- the mold is brought into close contact with a hot plate that has been heated to 500 ° C. in advance, and at the same time, a halogen lamp is irradiated to the movable mold (101) and the stamper (103). ) Surface temperature Before filling, the temperature was controlled at 200 ° C.
- thermoplastic resin is injected as pellets (130) from the hopper (1331) into the plasticizing cylinder (132), and is plasticized by rotating the screw (133). It is desirable that the pellets (130) are sufficiently degassed before plasticizing.
- the hopper ( 1 3 1) was evacuated while being heated in a sealed manner.
- the supercritical fluid may be mixed and infiltrated into the resin in the plasticized molten state, the force s, and when the mold is opened, the fluid escapes from inside the resin and the efficiency is poor. In the transfer process, the cavity was penetrated in a closed state.
- the injection mechanism of this embodiment adopts a pre-bra type, and at the time of plasticization, with the sealing mechanism (134) open as shown in Fig. 21, a band heater (135) controlled by heating is used.
- a band heater (135) controlled by heating By rotating the screw (1 3 3) in the wound plasticizing cylinder (1 3 2), the pellet (1 3 0) fed from the hopper (1 3 1) force is plasticized, and the seal It is charged through the mechanism (134) and forward of the injection plunger (136).
- the injection plunger (1 3 6) is guided by a ball retainer (1 3 9) on the inner wall of the injection cylinder (1 3 8), so that even with a narrow clearance, it can be driven smoothly without galling with the injection cylinder. It has become.
- the injection cylinder (138) and the nozzle (106) connected to its tip are heated by a band heater (137), and during the plasticization of the resin, the molten resin flows from the nozzle (106).
- the gate (108) is closed with a valve (107) controlled by a cylinder (113) mechanism to prevent leakage.
- the band heater (135) of the plasticizing cylinder (1 32) was controlled at 350 ° C
- the band heater (137) of the injection cylinder (138) and nozzle (106) was controlled at 370 ° C. .
- the gate (108) on the surface of the nozzle (106) is opened by the drive of the valve (107) linked to the cylinder mechanism (113).
- the injection plunger (136) moves forward in the injection cylinder (138) by the force of hydraulic pressure or the like, and the plasticized molten resin (109) is placed on the surface of the stamper (103) in the moving mold (101). ) Is filled.
- the moving mold (101) before filling is heated to a temperature equal to or higher than the glass transition of the thermoplastic resin, the molten resin contacts the mold surface and solidifies to form a skin layer on the surface. And low injection filling pressure.
- the degree of vacuum should be 1 ⁇ 10— it is desirable in the range of 2 ⁇ l X 1 0 3 P a, or may be an inert Gaz atmosphere such as carbon dioxide.
- FIG. 23 show conceptual diagrams of the forming method in the pressing step.
- the press mold (104) fixed to the mold clamping device (105) and heated and temperature-controlled was inserted.
- the method of controlling the temperature of the press mold (104) and the temperature setting are arbitrary, but in the present embodiment, a temperature control circuit through which cooling water using water (not shown) as a medium flows is used.
- the temperature was controlled at 145 ° C, which was slightly higher than the glass transition temperature of the resin material, and was lowered to 100 ° C halfway through the press.
- a supercritical fluid jetting piston (1 15) built in an air cylinder (1 17) is provided so as to move up and down.
- (1 15) is connected to a supercritical fluid generator (not shown) by a connecting hose (1 16), and the solenoid valve (not shown) is opened to eject supercritical fluid from the tip.
- an internal your (114) for introducing supercritical fluid, and when the core moves up and down, the ultra-low pressure in the press mold (104) is increased.
- the critical fluid flow paths (1 18) and (1 19) can be connected and disconnected.
- the supercritical fluid is completely sealed with O-rings (1 2 0) and (1 2 1) so that it does not leak out of the mold when the mold is closed.
- the resin surface at the transfer surface is at least transferred until the mold is pressurized and the microstructure such as the stamper (103) is transferred.
- the mold surface must be maintained at or above the glass transition temperature, and after the transfer is completed, must be lowered to or below the glass transition temperature.
- the moving mold (101) and the moving table (102) were brought into close contact with a cooling plate (not shown). The temperature of the cooling plate was controlled with 100 ° C water.
- the moving table (102) and the moving mold (101) with heat capacity take heat from the cooling plate and the temperature gradually decreases, but the moving mold (101) and the moving mold (101) take about 40 seconds.
- Stamper (10 3) The surface temperature was set to 140 ° C or lower, which is the glass transition temperature of the resin material, so that the transfer was completed by then.
- the supercritical fluid was introduced into the mold as shown in FIG.
- the mold clamping device (105) is driven by hydraulic pressure (not shown), and is installed on the press mold (104) fixed to it and on the outer periphery.
- the O-ring (1 20) is inserted into the movable mold (101)
- the supercritical fluid jetting biston (1 15) built in the air cylinder 1 (1 17) moves forward.
- the channels (1 18) and (1 1 9) are connected in the O-ring (1 2 0).
- the supercritical fluid generator passes through the connecting hose (1 16) and the flow paths (1 18) and (1 19) in the mold to pass the supercritical fluid. Is filled in a closed mold.
- the supercritical fluid using a-carbon dioxide (C_ ⁇ 2).
- the conditions under which carbon dioxide enters a supercritical state are a temperature of 31.1 and a pressure of 75.2 kgf / cm 2 , but in this embodiment, a temperature of 150 ° C. and a pressure of 200 kgf / cm 2 A supercritical state was established under the conditions of 2 .
- mold-transfer is performed in an environment that is at or above the supercritical temperature and pressure of carbon dioxide, thereby converting the carbon dioxide into a supercritical fluid. Can also be changed.
- the supercritical fluid jetting biston (1 15) is retracted as shown in Fig. 25, and the internal force is returned by the return spring (1 2 2).
- the core (1 1 4) retreats, the fluid flow paths (1 1 8) and (1 1 9) are cut off.
- a mold clamping force is generated in the mold clamping device (105) to pressurize between the cavities between the press mold (104) and the moving mold (101).
- thermoplastic resin material 109
- the mold clamping force is arbitrary. In the present invention, it is necessary to maintain the fluid in a supercritical state at least until the transfer is completed and the resin is solidified. After transferring 0 tons (pressure 509 kgf / cm 2 ) over 3 seconds, the mold clamping force was reduced to 5 tons (pressure 255 kgf / cm 2 ) to cool and solidify the resin. .
- Supercritical fluid that has permeated the resin escapes during solidification or curing Can be adjusted. If a large amount of supercritical fluid remains inside the resin, it will be difficult to suppress foaming during gasification during depressurization.
- the supercritical fluid jet piston (115) is advanced for 1 second during cooling while maintaining the mold clamping pressure, and excess supercritical fluid and volatile gas from inside the resin are discharged outside the mold. Missed.
- the injection molding method of the present invention As described above, according to the injection molding method of the present invention, satisfactory transfer cannot be obtained by the conventional molding method, and even an ultra-fine structure can be accurately transferred. In addition to obtaining mechanical properties, it is possible to improve production efficiency, for example, by replicating a large number of replicas. Further, the molded article obtained by the molding method of the present invention has a small and uniform retardation. It has low cross-sectional birefringence and excellent optical properties.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/478,415 US20040145086A1 (en) | 2001-05-22 | 2002-05-21 | Injection molding method |
JP2002591229A JP4184091B2 (ja) | 2001-05-22 | 2002-05-21 | 射出成形方法 |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001-151796 | 2001-05-22 | ||
JP2001151796 | 2001-05-22 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2002094532A1 true WO2002094532A1 (fr) | 2002-11-28 |
Family
ID=18996566
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2002/004869 WO2002094532A1 (fr) | 2001-05-22 | 2002-05-21 | Procede de moulage par injection |
Country Status (4)
Country | Link |
---|---|
US (1) | US20040145086A1 (ja) |
JP (1) | JP4184091B2 (ja) |
CN (1) | CN100391711C (ja) |
WO (1) | WO2002094532A1 (ja) |
Cited By (5)
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JP2005049829A (ja) * | 2003-07-14 | 2005-02-24 | Konica Minolta Holdings Inc | 微細形状を有する成形物、光学素子、成形方法及び成形装置 |
JP2005148666A (ja) * | 2003-11-20 | 2005-06-09 | Hitachi Maxell Ltd | 光学部品 |
JP2010527818A (ja) * | 2007-05-21 | 2010-08-19 | ディー アンド ディー マニュファクチュアリング | 圧縮成形のための成形材料の重力射出および関連する方法 |
JP2012506790A (ja) * | 2008-10-23 | 2012-03-22 | エルアールエム インダストリーズ インターナショナル,インク. | 無線制御による成形品の形成方法 |
JP2015201469A (ja) * | 2014-04-04 | 2015-11-12 | ダイヤモンド電機株式会社 | 内燃機関用点火コイルの製造方法 |
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CN100348401C (zh) * | 2002-05-22 | 2007-11-14 | 日立麦克赛尔株式会社 | 成形件,注射模塑法及装置 |
JP4264532B2 (ja) * | 2002-11-19 | 2009-05-20 | ソニー株式会社 | ディスク基板および光ディスク |
JP4030521B2 (ja) * | 2004-04-26 | 2008-01-09 | 日立マクセル株式会社 | ポリマーの表面改質方法 |
CA2567936C (en) | 2006-11-14 | 2016-01-05 | Atomic Energy Of Canada Limited | Device and method for surface replication |
WO2009023547A2 (en) | 2007-08-14 | 2009-02-19 | Arcxis Biotechnologies | Polymer microfluidic biochip fabrication |
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FR3029446B1 (fr) * | 2014-12-05 | 2017-01-13 | Plastic Omnium Cie | Moule pour la fabrication de piece en matiere plastique comportant un systeme pour realiser des orifices dans la piece |
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CN110667032B (zh) * | 2019-09-26 | 2021-10-26 | 上海珂明注塑系统科技有限公司 | 一种生产封盖用注塑设备 |
CN114953352B (zh) * | 2022-05-18 | 2023-05-05 | 武汉联塑精密模具有限公司 | 一种多规格简易伸缩节盖共模模具 |
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- 2002-05-21 WO PCT/JP2002/004869 patent/WO2002094532A1/ja active Application Filing
- 2002-05-21 US US10/478,415 patent/US20040145086A1/en not_active Abandoned
- 2002-05-21 JP JP2002591229A patent/JP4184091B2/ja not_active Expired - Fee Related
- 2002-05-21 CN CNB028103343A patent/CN100391711C/zh not_active Expired - Fee Related
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US4657714A (en) * | 1984-07-11 | 1987-04-14 | Matsushita Electric Industrial Co., Ltd. | Method and press molding apparatus for forming information carrier discs of granular thermoplastic material |
WO1994025242A1 (de) * | 1993-05-05 | 1994-11-10 | Boehringer Ingelheim Kg | Verfahren zur formgebung von thermoplastischen kunststoffen insbesondere von resorbierbaren thermoplasten |
JPH08142078A (ja) * | 1994-11-24 | 1996-06-04 | Kobe Steel Ltd | ロータリー式成形プレス |
US6042754A (en) * | 1998-10-30 | 2000-03-28 | Optima, Inc. | Continuous extrusion-compression molding process for making optical articles |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005049829A (ja) * | 2003-07-14 | 2005-02-24 | Konica Minolta Holdings Inc | 微細形状を有する成形物、光学素子、成形方法及び成形装置 |
JP4569744B2 (ja) * | 2003-07-14 | 2010-10-27 | コニカミノルタホールディングス株式会社 | 光学素子の成形方法 |
JP2005148666A (ja) * | 2003-11-20 | 2005-06-09 | Hitachi Maxell Ltd | 光学部品 |
JP4632657B2 (ja) * | 2003-11-20 | 2011-02-16 | 日立マクセル株式会社 | 光学部品 |
JP2010527818A (ja) * | 2007-05-21 | 2010-08-19 | ディー アンド ディー マニュファクチュアリング | 圧縮成形のための成形材料の重力射出および関連する方法 |
JP2012506790A (ja) * | 2008-10-23 | 2012-03-22 | エルアールエム インダストリーズ インターナショナル,インク. | 無線制御による成形品の形成方法 |
JP2015201469A (ja) * | 2014-04-04 | 2015-11-12 | ダイヤモンド電機株式会社 | 内燃機関用点火コイルの製造方法 |
Also Published As
Publication number | Publication date |
---|---|
CN100391711C (zh) | 2008-06-04 |
JPWO2002094532A1 (ja) | 2004-09-02 |
US20040145086A1 (en) | 2004-07-29 |
JP4184091B2 (ja) | 2008-11-19 |
CN1529649A (zh) | 2004-09-15 |
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