WO2017119398A1 - Procédé de fabrication d'un moulage tridimensionnel présentant une microstructure - Google Patents

Procédé de fabrication d'un moulage tridimensionnel présentant une microstructure Download PDF

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Publication number
WO2017119398A1
WO2017119398A1 PCT/JP2016/089126 JP2016089126W WO2017119398A1 WO 2017119398 A1 WO2017119398 A1 WO 2017119398A1 JP 2016089126 W JP2016089126 W JP 2016089126W WO 2017119398 A1 WO2017119398 A1 WO 2017119398A1
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WIPO (PCT)
Prior art keywords
fine structure
film
microstructure
dimensional molded
resin
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PCT/JP2016/089126
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English (en)
Japanese (ja)
Inventor
長澤　敦
功 浜島
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株式会社クラレ
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Publication of WO2017119398A1 publication Critical patent/WO2017119398A1/fr

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    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/02—Combined thermoforming and manufacture of the preform
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/16—Layered products comprising a layer of synthetic resin specially treated, e.g. irradiated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/02—Simple or compound lenses with non-spherical faces
    • G02B3/06—Simple or compound lenses with non-spherical faces with cylindrical or toric faces
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/02—Simple or compound lenses with non-spherical faces
    • G02B3/08—Simple or compound lenses with non-spherical faces with discontinuous faces, e.g. Fresnel lens

Definitions

  • the present invention relates to a method for manufacturing a three-dimensional molded body with a microstructure, and more particularly, to a method for manufacturing a three-dimensional molded body having a microstructure on the surface.
  • Non-Patent Document 1 discloses vacuum forming, pressure forming, vacuum / pressure forming, hot press forming, and the like.
  • vacuum forming, pressure forming, vacuum pressure forming, hot press forming, and forming methods similar to these methods are collectively referred to as “forming forming”.
  • Forming is a method of obtaining a three-dimensional molded body by heating and softening a resin film and bringing it into close contact with a mold.
  • the resin film is a film that can be wound into a roll and is a film made of a plastic material, and has a thickness of about 0.03 mm to 1 mm, for example.
  • Forming is characterized in that it is relatively easy to obtain a large three-dimensional molded body, the cost for manufacturing the mold is low, and the manufacturing period is short.
  • a three-dimensional molded body can be produced by processing the resin film with a fine structure using a forming method.
  • heating and softening the resin film with a fine structure may damage the precise fine structure formed on the surface of the resin film with a fine structure. Therefore, even if the forming molding conditions can be optimized in order to form the resin film three-dimensionally, it is difficult to obtain a desired three-dimensional molded body with a microstructure.
  • the present invention provides a method for producing a three-dimensional molded body with a fine structure, which is less likely to deform the fine structure.
  • the method for producing a microstructured three-dimensional molded body according to the present invention is as follows. Including a forming process for forming a microstructured resin film by forming a microstructured resin film;
  • the resin film with a fine structure includes a film main body made of a thermoplastic resin while having a thickness of 0.03 mm to 1 mm, and a fine structure layer covering the film main body,
  • the fine structure layer (for example, ionizing radiation curable resin 3) is made of a curable resin.
  • the development rate may be 110% or more.
  • the thickness T of the film body and the thickness t of the microstructure layer are T / 100 ⁇ t ⁇ T / 3 It is good also as satisfy
  • the curable resin may be an ionizing radiation curable resin.
  • the thermoplastic resin may transmit 10% or more of ionizing radiation.
  • the method may further include a step of continuously producing the resin film with a fine structure using a roll-to-roll method.
  • the fine structure layer includes a base layer and a fine structure portion provided in the base layer, and the fine structure portion includes a microlens, a prism lens, a cylindrical lens, a Fresnel lens, a height of 0.2 mm. It may be any one of a diffraction grating of 01 mm or less, a diffusion pattern composed of random irregularities, and a non-reflective structure having a height of 0.001 mm or less.
  • FIG. 3 is a plan view of a three-dimensional molded body with a microstructure according to the first embodiment;
  • FIG. 3 is a side view of the three-dimensional molded body with a microstructure according to the first embodiment.
  • 3 is a cross-sectional view of a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a flowchart showing a method for manufacturing a microstructured three-dimensional molded body according to the first embodiment.
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment. It is a figure which shows the spreading
  • FIG. 3 is a schematic diagram showing one step of a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 1 is a plan view of a three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 2 is a side view of the three-dimensional molded body with a microstructure according to the first embodiment.
  • FIG. 3 is a sectional view of the three-dimensional molded body with a microstructure according to the first embodiment.
  • the illustration of the fine structure portion 12b (described later) is omitted for easy viewing.
  • a microstructured three-dimensional molded body 10 includes a film body 11 having a bowl-shaped three-dimensional shape having a hemispherical surface, and a microstructure layer 12 covering a main surface outside the film body 11. Including.
  • the hemisphere according to the term hemisphere is not limited to one representing a half of a true sphere.
  • a curved surface similar in shape to the surface of a hemisphere composed of half of a true sphere is also included in the hemisphere of this embodiment.
  • the three-dimensional molded body 10 with a fine structure is a three-dimensional molded body having a bowl-shaped three-dimensional shape having a hemispherical surface.
  • the three-dimensional molded body 10 with a fine structure is a molded body having a bowl-shaped three-dimensional shape having a hemispherical surface.
  • the three-dimensional shape is not particularly limited, and may be any other shape.
  • the fine structure layer 12 may cover the inner main surface of the film body 11, or may cover both the outer main surface and the inner main surface.
  • the fine structure layer 12 may cover the entire surface of the film body 11 or only a part thereof.
  • the film body 11 is made of a thermoplastic resin.
  • a thermoplastic resin for example, a thermoplastic resin that transmits ionizing radiation can be used.
  • thermoplastic resins include polyester resins such as polyethylene terephthalate and polyethylene naphthalate, polyamide resins such as nylon 6, olefin resins such as polyethylene and polypropylene, vinyl resins such as polyvinyl chloride, and polymethyl.
  • acrylic resins such as methacrylate, and cellulose films such as polycarbonate and cellophane.
  • the film body 11 may be a copolymer resin having the above-described resin as a main component, a mixture, or a laminate having a plurality of layers made of the resin described above.
  • the film made of these thermoplastic resins may be an unstretched film, a uniaxially stretched film, or a biaxially stretched film.
  • the thermoplastic resin may be subjected to corona discharge treatment or plasma treatment, or easily applied by primer application. An adhesion treatment may be performed.
  • the fine structure layer 12 includes a base layer 12a and a fine structure portion 12b provided on the surface of the base layer 12a.
  • the fine structure layer 12 is made of a curable resin.
  • a curable resin a resin having a property of being cured by being given heat, ionizing radiation, or other energy is preferable.
  • ionizing radiation curable resins are preferable from the viewpoint of productivity. This is because curing can be accelerated by irradiating the ionizing radiation curable resin with ionizing radiation such as ultraviolet rays, visible rays, and infrared rays.
  • An example of the ionizing radiation curable resin is an ultraviolet curable resin.
  • the ionizing radiation curable resin is not particularly limited, and for example, a composition containing, as a main component, a radical polymerization acrylic resin or a cationic polymerization epoxy resin can be used. Moreover, you may add an ionizing radiation polymerization initiator, a dilution solvent, etc. to ionizing radiation curable resin suitably.
  • the fine structure portion 12b is a fine structure that controls light transmitted through the three-dimensional molded body 10 with a fine structure or imparts design properties to the three-dimensional molded body 10 with a fine structure.
  • controlling light has any of light collection, transmission, reflection, refraction, scattering, and diffraction with respect to light, or a function that causes a plurality of these phenomena. Means having at the same time.
  • Designability and “light control” may be collectively referred to as “high designability”.
  • the fine structure portion 12b does not have a particularly limited shape, but has a shape that controls the light emission direction, for example.
  • a fine structure examples include a microlens, a prism lens, a cylindrical lens, a Fresnel lens, a diffraction grating having a periodic structure, and a random uneven pattern having light diffusibility.
  • the size of the fine structure portion 12b is not limited.
  • the difference in height of the unevenness t that is, the height t of the microstructure 12b (see FIG. 3) is preferably 0.1 mm or less.
  • LED light emitting diode
  • the LED light source was disposed on the back side of the three-dimensional molded body 10 with a fine structure, and the LED light was irradiated to the three-dimensional molded body 10 with a fine structure. Then, this LED light permeate
  • FIG. 7 an image of a plurality of light rays diffusing so as to extend radially from the LED as the light source is formed.
  • the above-mentioned three-dimensional molded body 10 with a fine structure is an example. Therefore, as described above, LED light can be diffused by using the three-dimensional molded body 10 with various other shapes of microstructures. For this reason, it is possible to form light images having various shapes such as a substantially straight line shape, a substantially square shape, a substantially hexagonal star shape, a substantially cross shape, and two triangular shapes that touch each other at one point.
  • the wavelength dependence of the diffraction angle can be used.
  • the three-dimensional molded body with fine structure 10 can be used as an image eraser of a point light source such as an LED. Further, when the height t of the fine structure layer 12 (see FIG. 3) is suppressed to 0.01 mm or less, the three-dimensional molded body with fine structure 10 exhibits Mie scattering and light diffraction phenomena. Further, by suppressing the height t from the base layer 12a (see FIG. 3) to the fine structure portion 12b to 0.001 mm or less, the fine structure can be made to be a non-reflective structure.
  • FIG. 4 is a flowchart showing a method for manufacturing a three-dimensional molded body with a microstructure according to the first embodiment.
  • 5A to 5E and FIG. 6 are schematic views showing one step of the method for manufacturing the three-dimensional molded body with a microstructure according to the first embodiment.
  • a shape master is prepared (shape master preparation step S1).
  • the shape master 1 has a microstructure having a pattern shape substantially the same as the microstructure layer 12 of the microstructured three-dimensional molded body 10 (see FIG. 3).
  • the shape master 1 is produced by using a method such as photolithography using a photosensitive resin, mechanical cutting on a metal substrate or a plastic substrate.
  • a thin stamper 2 is manufactured by using a method such as electroforming treatment on the shape master 1 or mold making using a silicone resin (stamper manufacturing step S2).
  • the thin stamper 2 is obtained after the shape master 1 is produced.
  • the thin stamper may be produced directly without using the shape master.
  • Such a production method includes, for example, a production method using a Fresnel lathe or a roll lathe.
  • the ionizing radiation curable resin 3 is poured into the thin stamper 2 (resin casting step S3), and the film 4 is laminated on the ionizing radiation curable resin 3 (resin film forming step S4).
  • the film 4 corresponds to the film body 11 (see FIG. 1)
  • the ionizing radiation curable resin 3 corresponds to the fine structure layer 12 (see FIG. 1). That is, the film 4 is made of the same type of material as the film body 11.
  • a resin made of the same material as the fine structure layer 12 may be used.
  • the thickness of the film 4 is 1 mm or less so that the film 4 can be efficiently wound into a roll. Thereby, even when the roll-to-roll method is used for winding the film 4, the fine structure layer 12 can be satisfactorily formed, which is preferable. Specifically, when the film 4 is 1 mm or less, the film 4 can be easily wound on a roll, and the film 4 can be smoothly conveyed using a roll-to-roll system. Furthermore, preferably, the thickness of the film 4 is 0.5 mm or less. On the other hand, when the film 4 is an extremely thin film, problems such as generation of wrinkles in the film 4 and poor handling of the film 4 occur. For this reason, it is preferable that the thickness of the film 4 is 0.03 mm or more.
  • the ionizing radiation is irradiated so that the ionizing radiation directly hits the film 4 (ionizing radiation irradiation step S5).
  • the ionizing radiation source 90 is used to irradiate ionizing radiation.
  • a crosslinked structure is formed in the ionizing radiation curable resin 3.
  • the ionizing radiation curable resin 3 solidified by the crosslinked structure and the film 4 supporting the solidified ionizing radiation curable resin 3 are peeled from the thin stamper 2. Thereby, the resin film 5 with a fine structure is obtained (peeling process S6).
  • the resin film 5 with a fine structure may be a long resin film with a fine structure having such a laminated structure.
  • Such a long resin film with a fine structure may be continuously produced using a roll-to-roll method. Specifically, first, the thin stamper 2 is wound around a drum roll (not shown). Further, the film coated with the ionizing radiation curable resin having a predetermined thickness is conveyed to the drum roll and wound around the drum roll.
  • the resin film 5 with a fine structure can be obtained continuously by irradiating the ionizing radiation curable resin with the thin stamper 2 while making the ionizing radiation irradiate.
  • the resin film 5 with a fine structure includes a film 4 and an ionizing radiation curable resin 3.
  • the ionizing radiation curable resin 3 covers the film 4 and is solidified.
  • the solidified ionizing radiation curable resin 3 includes a base layer 3a and a fine structure portion 3b provided on the base layer 3a.
  • the base layer 3a corresponds to the base layer 12a (see FIG. 3)
  • the fine structure portion 3b corresponds to the fine structure portion 12b (see FIG. 3).
  • the fine structure portion 3b can have the same shape as various shapes of the fine structure portion 12b described above.
  • the thickness of the film 4 is T [mm] and the thickness of the ionizing radiation curable resin 3 is t [mm], the following relational expression 1 is satisfied.
  • the size of the thickness t is exaggerated for easy understanding.
  • the ionizing radiation curable resin 3 When t ⁇ T / 100, the ionizing radiation curable resin 3 is easily broken during forming. This is because the ionizing radiation curable resin 3 is too thin for forming. On the other hand, if t ⁇ T / 3, the deformation of the ionizing radiation curable resin 3 may not easily follow the deformation of the film 4. This is because the ionizing radiation curable resin 3 is too thick for forming. In this case, it may be difficult to give the three-dimensional shape to the ionizing radiation curable resin 3.
  • the elongation at break of the film 4 at a temperature at the time of forming is at least 10% because the film 4 is hardly broken at the time of forming.
  • the resin film 5 with a fine structure is prepared, and forming is performed (forming process S7).
  • forming process S7 an example using vacuum forming in forming will be described.
  • pressure forming, hot press forming, or a forming method close to these methods may be employed.
  • the mold 21 has a convex hemispherical portion 21a.
  • the material of the mold 21 may be plastic or wood.
  • it is preferable that the material of the mold 21 is a metal because the mold 21 exhibits high durability.
  • the mold 21 is accommodated in the lower chamber 32 of the forming apparatus 30 and the fine-structure resin film 5 is sandwiched between the upper chamber 31 and the lower chamber 32.
  • the mold 21 is installed in the lower chamber 32 so that the convex hemispherical portion 21a protrudes toward the upper chamber 31 side.
  • the gas existing in the space surrounded by the resin film 5 with fine structure and the mold 21 passes through the pipe 33 penetrating the lower chamber 32 and the mold 21.
  • the gas is discharged out of the lower chamber 32.
  • the space surrounded by the resin film 5 with a fine structure and the mold 21 is brought into a vacuum state. And the resin film 5 with a fine structure is heated.
  • the temperature at this time is not limited, it is generally preferable to heat to a temperature equal to or higher than the glass transition temperature of the thermoplastic resin constituting the film 4 by about 50 ° C. This is because if the temperature is lower than this, the film 4 is difficult to stretch, and conversely if the temperature is high, the film 4 is deformed and thus forming molding becomes difficult.
  • the three-dimensional structure when a desired three-dimensional structure is a complicated shape, the three-dimensional structure can be faithfully reproduced by a method called vacuum / pressure forming.
  • vacuum / pressure forming compressed air is introduced into the inner space 31 a of the upper chamber 31. For this reason, the pressure concerning the resin film 5 with a fine structure can be made stronger than atmospheric pressure.
  • the three-dimensional molded body 10 with fine structure can be obtained.
  • the film 4 in the resin film 5 with a fine structure corresponds to the film body 11 of the three-dimensional molded body 10 with the fine structure
  • the ionizing radiation curable resin 3 corresponds to the fine structure layer 12.
  • the film 4 and the ionizing radiation curable resin 3 satisfy the relational expression 1, the ionizing radiation curable resin 3 is not easily broken in the forming step S7. For this reason, when the deformation of the ionizing radiation curable resin 3 follows the deformation of the film 4, a three-dimensional shape can be easily given to the resin film 5 with a fine structure. Therefore, the three-dimensional molded body 10 with a fine structure can be manufactured stably.
  • the development rate Dr in the forming step S7 is 110% or more.
  • the expansion rate Dr is a percentage of the post-molding area A2 with respect to the pre-molding area A1, and is expressed using the following relational expression 2.
  • the pre-molding area A1 is an area before molding of the part molded in the forming process S7 in the resin film 5 with a fine structure.
  • the post-molding area A2 is the area of the three-dimensional surface generated by molding in the forming process S7 in the three-dimensional molded body 10 with a fine structure.
  • the three-dimensional compact 10 with a microstructure is a bowl-shaped three-dimensional film having a hemispherical surface with a diameter 2r and a height r
  • the pre-molding area A1 is ( ⁇ r 2 )
  • the post-molding area A2 is the (4 ⁇ r 2/2).
  • the development rate Dr is calculated as 200% using the relational expression 2.
  • the development rate Dr can also be obtained using the following procedure. First, before carrying out the forming step S7, the unit cell is directly written on the resin film 5 with a fine structure. Next, after completing the forming step S7, the expansion rate of each unit cell is obtained. Further, the development rate Dr is obtained by weighted averaging the obtained development rates. Even when the microstructure portion 12b of the three-dimensional molded body 10 with a microstructure has a complicated shape, the development rate Dr can be obtained by using such a procedure.
  • the microstructure layer 12 is made of a curable resin, the microstructure layer 12 is not easily deformed in the forming process S7. For this reason, the microstructure layer 12 can maintain its shape even after forming. Therefore, in Embodiment 1, the three-dimensional molded body 10 with a fine structure can be manufactured stably.
  • the three-dimensional molded body with a microstructure according to the first embodiment includes a main body of equipment such as daily necessities and daily necessities, containers for food and various articles, casings such as electronic equipment and office supplies, interiors for automobiles, and games. It can also be used for uses of amusement devices such as machines, toys, and game machines, and other uses.
  • a main body of equipment such as daily necessities and daily necessities, containers for food and various articles, casings such as electronic equipment and office supplies, interiors for automobiles, and games. It can also be used for uses of amusement devices such as machines, toys, and game machines, and other uses.
  • an LED that is a simple point light source can be used as a linear light source illumination, a surface light source illumination, or a characteristic design illumination. Can be used.
  • the three-dimensional molded body with a microstructure according to the first embodiment is not limited to the applications listed here, and can be applied to various applications.
  • the method of manufacturing the resin film 5 with a fine structure using the ionizing radiation curable resin is not limited to the manufacturing method including the shape master preparation step S1 to the peeling step S6 described above.
  • Other manufacturing methods can also be applied to this embodiment.
  • a manufacturing method for example, there is a manufacturing method by a roll-to-roll method.
  • a roll-to-roll manufacturing method is preferable because it has high productivity.
  • a pair of rolls 43 and 44 are respectively opposed to a roll 42 around which a stamper 41 having a surface shape obtained by inverting the surface shape of the microstructure layer 12 (see FIG. 3) is wound.
  • the stamper 41 has a flat surface portion 41a and a concave portion 41b.
  • the recess 41b has the same shape as the inverted shape of the fine structure portion 3b (see FIG. 5E).
  • the recessed part 41b is described in FIG. 8, it may be a convex part. In this case, the fine structure formed in the fine-structured resin film 5 has a concave shape.
  • a UV (Ultraviolet) lamp 45 is arranged between the pair of rolls 43 and 44 as an ionizing radiation source. More specifically, the UV lamp 45 irradiates ultraviolet rays in a predetermined direction. The direction of the UV lamp 45 is adjusted such that the ultraviolet rays emitted from the UV lamp 45 are applied to the outer peripheral surface of the roll 42.
  • the film 4 coated with the ionizing radiation curable resin 3 is sandwiched between the roll 42 and each of the pair of rolls 43 and 44. Further, the film 4 is passed between the roll 42 and each of the pair of rolls 43 and 44. While the film 4 passes, the surface shape of the stamper 41 is transferred to the ionizing radiation curable resin 3 by irradiating the ionizing radiation curable resin 3 and the stamper 41 with ionizing radiation. Then, the base layer 3a and the fine structure portion 3b are formed in the ionizing radiation curable resin 3. As described above, the resin film 5 with a fine structure is formed.
  • Example 1 The manufacturing conditions of Example 1 will be described.
  • a shape master is produced by forming a fine uneven pattern on the photosensitive resin arranged on the glass substrate.
  • the fine concavo-convex pattern is formed by a photolithography method using a photomask.
  • the fine concavo-convex pattern of the present embodiment is a hexagonal close-packed array pattern in which a plurality of cylinders are arranged on a plane.
  • the height of the cylinder was 0.001 mm and the diameter was 0.001 mm.
  • the pitch of the cylinders in the hexagonal close-packed array was 0.002 mm.
  • the size of the region where the fine unevenness pattern was formed was 150 mm ⁇ 150 mm.
  • a nickel metal thin film having a thickness of about 0.3 mm is formed on the shape master by performing nickel electroforming on the obtained shape master. Then, by carefully peeling the nickel metal thin film from the shape master, a thin stamper made of the nickel metal thin film is obtained.
  • the fine structure formed on the surface of the thin stamper has a shape inverted with respect to the fine structure of the shape master.
  • a cylindrical hole is formed on the surface of the thin stamper.
  • the cylindrical holes are a plurality of holes formed by a columnar space.
  • a tape having a thickness of 0.01 mm is applied to the outer periphery of the thin stamper.
  • the thickness of the ultraviolet curable resin is controlled by the thickness of the tape.
  • the thickness t of the ultraviolet curable resin layer in the resin film with a fine structure is about 0.01 mm.
  • an acrylic ultraviolet curable resin manufactured by Hitachi Chemical Co., Ltd .: Elfort 1001-D2 is dropped onto the thin stamper.
  • step S4 extra acrylic ultraviolet rays are removed from the thin stamper by laminating a polycarbonate film having a thickness T of 0.2 mm (Mitsubishi Gas Chemical Co., Ltd .: Iupilon FE-2000) using a hand roller. Remove the curable resin.
  • a polycarbonate film having a thickness T of 0.2 mm Mitsubishi Gas Chemical Co., Ltd .: Iupilon FE-2000
  • the acrylic ultraviolet curable resin is polymerized and solidified by irradiating ultraviolet rays having an illuminance of 100 mW / cm 2 and an integrated light quantity of 1000 mJ / cm 2 from the polycarbonate film side.
  • the polycarbonate film was peeled from the thin stamper, whereby a 150 mm ⁇ 150 mm size resin film with a fine structure could be obtained.
  • cylinders having a height of 0.001 mm and a diameter of 0.001 mm are closely arranged in a hexagonal manner with a pitch of 0.002 mm.
  • the thickness T of the polycarbonate film is 0.2 mm
  • the thickness t of the ultraviolet curable resin layer in the resin film with a fine structure is approximately 0.01 mm.
  • T / 100 and T / 3 have the following values.
  • the thickness T of the polycarbonate film and the thickness t of the ultraviolet curable resin layer satisfy the relational expression 1.
  • a vacuum / pressure forming machine (Fuse Vacuum Co., Ltd .: vacuum / pressure forming machine NGF-0406-S type) was used.
  • the resin film with a fine structure was set so that the polycarbonate film side faced or contacted the metal mold side. After setting, the resin film with fine structure was formed.
  • the obtained microstructured three-dimensional molded body was a film-shaped body having a bowl-shaped three-dimensional shape reflecting a metal-shaped hemispherical convex portion.
  • a cylindrical pattern was formed on the main surface outside the membrane. Further, in the three-dimensional molded body with a fine structure, the development rate was 200%.
  • White light was incident from one white LED on each of the resin film with a microstructure obtained in the peeling step S6 and the three-dimensional molded body with a microstructure obtained in the forming step S7. Then, it has confirmed that the fine structure formed in the surface of the resin film with a fine structure and the three-dimensional molded object with a fine structure was causing the diffraction phenomenon. In addition, 0th-order light, 1st-order light, 2nd-order light, and higher-order diffracted light were generated from white light by the diffraction phenomenon.
  • Example 2 a resin film with a microstructure and a three-dimensional molded body with a microstructure are manufactured using the same manufacturing method as in Example 1 except for the forming molding step S7.
  • the shape master preparation step S1 to the peeling step S6 are performed.
  • the resin film with a fine structure was formed by a press method (Nagai Mfg. Co., Ltd .: match forming method FILMOLD (registered trademark)).
  • a convex hemispherical metal mold having a convex hemispherical part having a diameter of 50 mm and a height of 25 mm and a concave hemispherical metal mold having a concave hemispherical part having a diameter of 50 mm and a height of 25 mm are prepared in advance.
  • the resin film with a fine structure is set so that the surface on the polycarbonate film side faces or contacts the concave hemispherical metal mold side.
  • forming was performed by pressing a resin film with a fine structure using a convex hemispherical metal mold and a concave hemispherical metal mold.
  • the obtained three-dimensional molded body with a fine structure was a film-like body having a shape reflecting the convex hemispherical portion of the metal mold.
  • a cylindrical pattern is formed on the inner main surface of the film-like body.
  • the three-dimensional molded body with a fine structure has a development rate of 200%.
  • Comparative Example 1 a resin film with a microstructure and a three-dimensional molded body with a microstructure are manufactured using the same manufacturing method as in Example 1 except for the resin casting step S3 and the resin film forming step S4.
  • the same thin stamper as in Example 1 was used.
  • a 0.05 mm thick tape is applied to the outer periphery of the thin stamper.
  • the thickness of the ultraviolet curable resin is controlled by the thickness of the tape.
  • the thickness t of the ultraviolet curable resin layer in the resin film with a fine structure is about 0.05 mm.
  • step S4 extra acrylic ultraviolet rays are removed from the thin stamper by laminating a polycarbonate film (Mitsubishi Gas Chemical Co., Ltd .: Iupilon FE-2000) having a thickness T of 0.1 mm using a hand roller. Remove the curable resin.
  • a polycarbonate film Mitsubishi Gas Chemical Co., Ltd .: Iupilon FE-2000
  • Example 1 The same manufacturing conditions as in Example 1 were used in the ionizing radiation irradiation step S5 and the peeling step S6. As described above, the resin film with structure can be obtained through the resin pouring step S3 to the peeling step S6.
  • the thickness T of the polycarbonate film is 0.1 mm
  • the thickness t of the ultraviolet curable resin layer in the resin film with a fine structure is about 0.05 mm.
  • T / 100 and T / 3 have the following values.
  • the assumed three-dimensional molded body with a microstructure was not obtained. This was considered to be because the ultraviolet curable resin could not follow the deformation of the polycarbonate film because the ultraviolet curable resin was too thick.
  • Comparative Example 2 a resin film with a microstructure and a three-dimensional molded body with a microstructure are manufactured using the same manufacturing method as in Example 1 except for the resin casting step S3 and the resin film forming step S4.
  • the same thin stamper as in Example 1 was used in the resin pouring step S3. Without using tape or the like on the outer periphery of this thin stamper, it was used as it was in the next resin film forming step S4.
  • the thickness t of the ultraviolet curable resin layer in the resin film with a fine structure was about 0.003 mm.
  • step S4 extra acrylic ultraviolet rays are removed from the thin stamper by laminating a polycarbonate film (Mitsubishi Gas Chemical Co., Ltd .: Iupilon FE-2000) having a thickness T of 0.5 mm using a hand roller. Remove the curable resin.
  • a polycarbonate film Mitsubishi Gas Chemical Co., Ltd .: Iupilon FE-2000
  • Example 1 The same manufacturing conditions as in Example 1 were used in the ionizing radiation irradiation step S5 and the peeling step S6. As described above, the resin film with structure can be obtained through the resin pouring step S3 to the peeling step S6.
  • the thickness T of the polycarbonate film is 0.1 mm
  • the thickness t of the ultraviolet curable resin layer in the resin film with a fine structure is approximately 0.003 mm.
  • T / 100 and T / 3 have the following values.
  • a three-dimensional molded body with a fine structure was obtained through the resin pouring step S3 to the forming step S7.
  • the obtained microstructured three-dimensional molded body was a film-shaped body having a bowl-shaped three-dimensional shape reflecting a metal-shaped hemispherical convex portion.
  • a cylindrical pattern was formed on the main surface outside the membrane. Further, the three-dimensional molded body with a fine structure had a development rate of 200%.
  • a method using a three-dimensional molding matrix made of metal is conceived.
  • the three-dimensional molding die is called a mold or a stamper.
  • a shape in which a male and a female are inverted is formed on the surface as a fine structure.
  • a molten thermoplastic resin is molded using a three-dimensional molding matrix. Examples of the method for molding the thermoplastic resin include injection molding and hot press molding.
  • a method for producing a three-dimensional forming mother die there is a method in which an inverted shape of a fine structure is directly formed by mechanical cutting on the surface of a mother die that has been processed in advance to the outer dimensions of a three-dimensional formed body.
  • the three-dimensional molded body has a shape having a three-dimensional curved surface, it is difficult to produce a three-dimensional molding matrix by mechanical cutting when a fine structure must be formed on the three-dimensional curved surface. .
  • a method of manufacturing a three-dimensional molded body with a fine structure a method of forming a fine structure without directly forming a fine structure on a three-dimensional forming matrix is conceived.
  • a thin plate called a thin stamper on which a fine structure is formed is used in combination with a three-dimensional forming mother die to form a fine structure.
  • a shape master having a fine structure similar to the fine structure to be formed on the surface of the three-dimensional molded body is prepared in advance by a highly accurate method such as photolithography. By performing nickel electroforming on the shape master, a thin stamper that is an inversion type of a fine structure is produced.
  • a three-dimensional molded body with a fine structure can be obtained.
  • a shape master produced by photolithography or the like is usually produced on a planar substrate made of glass or silicon, only a planar stamper can inevitably be produced. Therefore, it is difficult to apply the stamper method to manufacture a three-dimensional molded body having a curved surface.
  • a process or stamper for forming the microstructure by mechanical cutting or the like is performed.
  • the manufacturing process is very time consuming and must be expensive.
  • the three-dimensional molding die is damaged or when the three-dimensional molding die reaches the end of its life, the three-dimensional molding die must be remanufactured. Therefore, manufacturing a three-dimensional molded body with a fine structure by these methods leads to an increase in cost of the product. That is, the manufacturing method of the microstructured three-dimensional molded body according to the first embodiment is lower in cost than such a manufacturing method.
  • a method of performing forming molding on a resin film in which a fine structure is previously formed of a thermoplastic resin is conceived.
  • a microstructure layer made of a thermoplastic resin is formed in advance by injection molding or hot pressing.
  • the fine structure is likely to be deformed by heating at the time of forming, and the shape thereof may not be maintained.
  • the manufacturing method of a three-dimensional molded body with a microstructure according to the first embodiment is less likely to deform, and can stably manufacture a three-dimensional molded body with a microstructure. it can.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un moulage tridimensionnel présentant une microstructure, le procédé réduisant les risques de déformation de la microstructure. Ce procédé comprend une étape de formation (S7) pour former un film de résine (5) doté d'une microstructure afin de produire un moulage tridimensionnel (10) présentant une microstructure. Le film de résine (5) doté d'une microstructure comporte un corps de film principal (4) d'une épaisseur de 0,03 mm à 1 mm, fabriqué à partir d'une résine thermoplastique, et une couche de microstructure (3) recouvrant le corps de film principal (4). La couche de microstructure (3) est fabriquée à partir d'une résine thermodurcissable.
PCT/JP2016/089126 2016-01-04 2016-12-28 Procédé de fabrication d'un moulage tridimensionnel présentant une microstructure WO2017119398A1 (fr)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108150966A (zh) * 2017-12-26 2018-06-12 汉舟四川环保科技有限公司 基于微纳结构的光学照明透镜

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012081619A (ja) * 2010-10-08 2012-04-26 Kuraray Co Ltd 表面凹凸パターンを有する部材の製造方法
JP2013226667A (ja) * 2012-04-24 2013-11-07 Kuraray Co Ltd 微細凹凸を有するシート状部材の製造方法およびシート状部材
WO2014069535A1 (fr) * 2012-10-31 2014-05-08 株式会社クラレ Procédé de fabrication d'un corps en résine moulée présentant une structure fine

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012081619A (ja) * 2010-10-08 2012-04-26 Kuraray Co Ltd 表面凹凸パターンを有する部材の製造方法
JP2013226667A (ja) * 2012-04-24 2013-11-07 Kuraray Co Ltd 微細凹凸を有するシート状部材の製造方法およびシート状部材
WO2014069535A1 (fr) * 2012-10-31 2014-05-08 株式会社クラレ Procédé de fabrication d'un corps en résine moulée présentant une structure fine

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108150966A (zh) * 2017-12-26 2018-06-12 汉舟四川环保科技有限公司 基于微纳结构的光学照明透镜

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