JP2006168314A - Molded article having fine protrusion shape and/or fine recess shape, its manufacturing method and mold - Google Patents
Molded article having fine protrusion shape and/or fine recess shape, its manufacturing method and mold Download PDFInfo
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Abstract
Description
本発明は、微細凸形状および／または微細凹形状を有する成形品とその製造方法と金型装置に関するものである。さらに詳しくは、高アスペクト比の微細凸形状および／または微細凹形状を有する光学部品等を造出するための樹脂成形品或いはガラス成形品とその製造方法と金型装置に関するものである。 The present invention relates to a molded article having a fine convex shape and / or a fine concave shape, a manufacturing method thereof, and a mold apparatus. More specifically, the present invention relates to a resin molded product or glass molded product for producing an optical component having a fine convex shape and / or a fine concave shape with a high aspect ratio, a manufacturing method thereof, and a mold apparatus.
一般にＣＤ、ＤＶＤ等の表面に微細形状が存在する成形品の製造については、その微細形状の転写性が大きな問題となる。
例えば特許文献１、特許文献２等により、ＣＤ、ＤＶＤ等の光ディスク成形品をキャビティに樹脂を流し込んで成形する技術が開示されている。しかし、これらＣＤ、ＤＶＤ等の光ディスク成形品は、微細形状の幅は１μｍ程度でアスペクト比も小さい（０．２程度）ために容易に成形することができたものであり、高アスペクト比の微細凸形状および／または微細凹形状の成形へ適用されるものではない。
In general, for the production of a molded product having a fine shape on the surface of a CD, DVD or the like, the transferability of the fine shape is a big problem.
For example,
また、半導体素子や回折格子などの微小光学素子を樹脂を用いて製造する方法として、成形面に微細凹形状または微細凸形状を有する金型を用いて樹脂をプレスすることによって樹脂の表面に高アスペクト比の微細凸形状を有する樹脂成形品を製造する加工方法があるが、この加工方法の例としては、特許文献３（本件発明者の一人による）において、高アスペクト比の微細凸形状の加工例が示されている。この方法では、金型表面を高分子樹脂でコーティングして離型剤を用いる必要をなくすことによって、この離型剤の阻害を受けることがなくなり金型の微細凹形状を樹脂に転写できるとしている。ところで、金型の高アスペクト比の微細凹形状を転写する際、転写される樹脂が金型のキャビティ部に十分に回り込むかどうかが重要な問題であるが、該特許文献３では、これに対する対策を講じておらず、加工例のアスペクト比も２にとどまっていた。このような加工法を用いて、樹脂にアスペクト比が２を超える微細凸形状を樹脂へ転写する例は示されていなかった。 In addition, as a method of manufacturing a micro-optical element such as a semiconductor element or a diffraction grating using a resin, the resin surface is pressed by using a mold having a fine concave shape or a fine convex shape on the molding surface. There is a processing method for producing a resin molded product having a fine convex shape with an aspect ratio. As an example of this processing method, in Patent Document 3 (by one of the inventors), processing of a fine convex shape with a high aspect ratio is performed. An example is shown. In this method, the mold surface is coated with a polymer resin to eliminate the need to use a mold release agent, thereby preventing the mold release agent from being hindered and transferring the fine concave shape of the mold to the resin. . By the way, when transferring a fine concave shape with a high aspect ratio of a mold, it is an important problem whether or not the transferred resin sufficiently wraps around the cavity of the mold. The aspect ratio of the processing example was only 2. An example in which a fine convex shape having an aspect ratio of more than 2 is transferred to a resin using such a processing method has not been shown.
本発明は、この課題を解決するべく行われたものであり、特別な装置、部品を使用することなく容易にアスペクト比が２を超えるような微細凸形状または微細凹形状を有する樹脂またはガラス成形品を造出することができる成形品の製造方法を提供することを目的とする。 The present invention has been made to solve this problem, and is a resin or glass molding having a fine convex shape or a fine concave shape whose aspect ratio easily exceeds 2 without using a special device or component. It is an object of the present invention to provide a method for producing a molded product capable of producing a product.
上記課題を解決するための本発明は、以下の技術的手段から構成される。
（１）成形面に微細凹形状および／または微細凸形状を有する金型を用いて被成形物をプレスすることにより被成形物の表面に高アスペクト比の微細凸形状および／または微細凹形状を有する成形品を製造する方法において、金型の成形面に形成された高アスペクト比の微細凹形状部および／または微細凸形状部の周りに、土手を形成した金型を用いることを特徴とする高アスペクト比の微細凸形状および／または微細凹形状を有する成形品の製造方法。
（２）金型の微細凹形状および／または微細凸形状のまわりに形成する土手の高さが、成形面に微細凹形状のみを有する金型の時にはその微細凹形状の最大の深さ以上であることを、成形面に微細凸形状のみを有する金型の時にはその微細凸形状の最大の高さの２倍以上であることを、成形面に微細凹形状かつ微細凸形状を有する時には最大の深さと最大の高さの２倍との和以上であることを特徴とする上記（１）記載の高アスペクト比の微細凸形状および／または微細凹形状を有する成形品の製造方法。
（３）成形面に微細凹形状および／または微細凸形状が成形された金型について、微細凹形状のアスペクト比（深さ／幅）が２より大きくなる形状および／または、隣接した微細凸形状の間または微細凸形状と土手の間に形成される凹形状のアスペクト比（高さ／間隔）が２より大きくなる形状を含むことを特徴とする上記（１）、（２）記載の高アスペクト比の微細凸形状および／または微細凹形状を有する成形品の製造方法。
（４）成形面に微細凹形状および／または微細凸形状が成形された金型について、微細凹形状のアスペクト比（深さ／幅）が１２より大きくなる形状および／または、隣接した微細凸形状の間または微細凸形状と土手の間に形成される凹形状のアスペクト比（高さ／間隔）が１２より大きくなる形状を含むことを特徴とする上記（１）〜（３）記載の高アスペクト比の微細凸形状および／または微細凹形状を有する成形品の製造方法。
（５）金型の微細凹形状および／または微細凸形状のまわりに形成する土手の高さが、成形面に微細凹形状のみを有する金型の時にはその微細凹形状の最大の深さの３倍以上であることを、成形面に微細凸形状のみを有する金型の時にはその微細凸形状の最大の高さの６倍以上であることを、成形面に微細凹形状かつ微細凸形状を有する時には最大の深さと最大の高さの２倍との和の３倍以上であることを特徴とする上記（１）〜（４）記載の高アスペクト比の微細凸形状および／または微細凹形状を有する成形品の製造方法。
（６）被成形物が樹脂またはガラスであることを特徴とする上記（１）〜（５）のいずれかに記載の高アスペクト比の微細凸形状および／または微細凹形状を有する成形品の製造方法。
The present invention for solving the above-described problems comprises the following technical means.
(1) By pressing a molding using a mold having a fine concave shape and / or a fine convex shape on the molding surface, the surface of the molding has a fine convex shape and / or a fine concave shape with a high aspect ratio. In the method for producing a molded product having a high-aspect-ratio fine concave-shaped portion and / or a fine convex-shaped die formed on the molding surface of the mold is used. A method for producing a molded article having a fine convex shape and / or a fine concave shape with a high aspect ratio.
(2) The height of the bank formed around the fine concave shape and / or fine convex shape of the mold is not less than the maximum depth of the fine concave shape when the mold has only the fine concave shape on the molding surface. When the mold has only a fine convex shape on the molding surface, it is more than twice the maximum height of the fine convex shape. The method for producing a molded article having a fine convex shape and / or a fine concave shape with a high aspect ratio according to the above (1), which is at least the sum of the depth and twice the maximum height.
(3) For a mold having a fine concave shape and / or fine convex shape formed on the molding surface, a shape in which the aspect ratio (depth / width) of the fine concave shape is greater than 2 and / or an adjacent fine convex shape The aspect ratio (height / spacing) of the concave shape formed between the fine convex shape and the bank includes a shape having an aspect ratio (height / interval) larger than 2. The high aspect according to the above (1) and (2) A method for producing a molded product having a fine convex shape and / or a fine concave shape.
(4) For a mold having a fine concave shape and / or fine convex shape formed on the molding surface, a shape in which the aspect ratio (depth / width) of the fine concave shape is greater than 12, and / or an adjacent fine convex shape The aspect ratio (height / spacing) of the concave shape formed between the fine convex shape and the bank includes a shape having an aspect ratio (height / interval) larger than 12. The high aspect according to any one of the above (1) to (3) A method for producing a molded product having a fine convex shape and / or a fine concave shape.
(5) When the height of the bank formed around the fine concave shape and / or fine convex shape of the mold is a mold having only the fine concave shape on the molding surface, the maximum depth of the fine concave shape is 3 If the mold has only a fine convex shape on the molding surface, the molding surface has a fine concave shape and a fine convex shape that is six times the maximum height of the fine convex shape. The fine convex shape and / or the fine concave shape with a high aspect ratio according to the above (1) to (4), which is sometimes more than three times the sum of the maximum depth and twice the maximum height. A method for producing a molded product.
(6) Production of molded article having high aspect ratio fine convex shape and / or fine concave shape according to any one of (1) to (5) above, wherein the molding is resin or glass Method.
（７）成形面に微細凹形状および／または微細凸形状を有する金型を用いて被成形物をプレスすることにより被成形物の表面に高アスペクト比の微細凸形状および／または微細凹形状を有する成形品を製造するための金型装置において、金型の成形面に形成された高アスペクト比の微細凹形状部および／または微細凸形状部の周りに土手を形成した金型を設けたことを特徴とする金型装置。
（８）前記土手の高さが、成形面に微細凹形状のみを有する金型の時にはその微細凹形状の最大の深さ以上であることを、成形面に微細凸形状のみを有する金型の時にはその微細凸形状の最大の高さの２倍以上であることを、成形面に微細凹形状かつ微細凸形状を有する時には最大の深さと最大の高さの２倍との和以上であることを特徴とする上記（７）記載の金型装置。
（９）前記金型が、微細凹形状のアスペクト比（深さ／幅）が２より大きくなる形状および／または、隣接した微細凸形状の間または微細凸形状と土手の間に形成される凹形状のアスペクト比（高さ／間隔）が２より大きくなる形状を含むことを特徴とする上記（７）、（８）記載の金型装置。
（１０）前記金型が、微細凹形状のアスペクト比（深さ／幅）が１２より大きくなる形状および／または、隣接した微細凸形状の間または微細凸形状と土手の間に形成される凹形状のアスペクト比（高さ／間隔）が１２より大きくなる形状を含むことを特徴とする上記（７）〜（９）のいずれかに記載の金型装置。
（１１）アスペクト比が１２より大きい微細凸形状および／または微細凹形状を有する成形品。
（１２）樹脂またはガラスからなる上記（１１）に記載の成形品。
(7) By pressing the molding using a mold having a fine concave shape and / or fine convex shape on the molding surface, the surface of the molding has a fine convex shape and / or fine concave shape with a high aspect ratio. In a mold apparatus for producing a molded product having a high-aspect-ratio fine concave-shaped part formed on the molding surface of the mold and / or a mold having a bank formed around the fine convex-shaped part Mold device characterized by.
(8) When the height of the bank is a mold having only a fine concave shape on the molding surface, it is equal to or greater than the maximum depth of the fine concave shape. Sometimes it is at least twice the maximum height of the fine convex shape, and when it has a fine concave shape and fine convex shape on the molding surface, it must be at least the sum of the maximum depth and twice the maximum height. The mold apparatus according to (7) above, characterized in that
(9) The mold has a shape in which the aspect ratio (depth / width) of the fine concave shape is larger than 2 and / or a concave formed between adjacent fine convex shapes or between the fine convex shape and the bank. The mold apparatus according to (7) or (8) above, wherein the mold apparatus includes a shape having an aspect ratio (height / interval) greater than 2.
(10) The mold has a shape in which the aspect ratio (depth / width) of the fine concave shape is greater than 12, and / or a concave formed between adjacent fine convex shapes or between the fine convex shape and the bank. The mold apparatus according to any one of (7) to (9) above, wherein the mold apparatus includes a shape having an aspect ratio (height / interval) greater than 12.
(11) A molded product having a fine convex shape and / or a fine concave shape having an aspect ratio of greater than 12.
(12) The molded article according to (11), which is made of resin or glass.
本発明によると、成形面に微細凹形状および／または微細凸形状を有する金型を用いて被成形物をプレスすることにより被成形物の表面に高アスペクト比の微細凸形状および／または微細凹形状を有する成形品を製造する方法において、成形面に形成された高アスペクト比の微細凹形状部および／または微細凸形状部の周りに、成形面に微細凹形状のみを有する金型の時にはその微細凹形状の最大の深さ以上の、成形面に微細凸形状のみを有する金型の時にはその微細凸形状の最大の高さの２倍以上の、成形面に微細凹形状かつ微細凸形状を有する時には最大の深さと最大の高さの２倍との和以上の土手を形成することにより、アスペクト比が２より大きい微細凸形状および／または微細凹形状を有する成形品の製造を容易に行うことができる。 According to the present invention, by pressing a molding using a mold having a fine concave shape and / or fine convex shape on the molding surface, a fine convex shape and / or fine concave having a high aspect ratio is formed on the surface of the molding. In the method of manufacturing a molded product having a shape, when the mold has only a fine concave shape on the molding surface around the fine concave shape portion and / or the fine convex shape portion of the high aspect ratio formed on the molding surface, In the case of a mold having only a fine convex shape on the molding surface that is not less than the maximum depth of the fine concave shape, a fine concave shape and a fine convex shape on the molding surface that is at least twice the maximum height of the fine convex shape. By forming a bank that is equal to or greater than the sum of the maximum depth and twice the maximum height, a molded article having a fine convex shape and / or a fine concave shape having an aspect ratio larger than 2 can be easily produced. It is possible .
以下本発明の実施の形態について図面を参照して説明する。本発明に係る成形品の製造方法は、片面が微細な凸形状および／または凹形状を示す様々の目的の基板の形成に適応できる。 Embodiments of the present invention will be described below with reference to the drawings. The method for producing a molded product according to the present invention can be applied to the formation of substrates for various purposes in which one side has a fine convex shape and / or a concave shape.
図１〜図３は金型（４）を示す図であり、図４はプレス機を用いて被成形物に成形する様子を示す図であり、図５〜図７はそれぞれ図１〜図３の金型を用いて成形されて得られた成形品（１１）を表す図である。
図１〜図３に示すように金型の成形面の高アスペクト比の微細凹形状部および／または微細凸形状の周りには、土手（１０）が形成されている。ここで、金型の成形面において微細凸形状および／または微細凹形状部の周りの土手部までの平滑な面を金型の基準面（２２）とし、この基準面からみた凹凸関係により金型の成形面の微細形状を微細凹形状或いは微細凸形状とする。図４に示すように、金型を成形に用いるプレス機上部（６）に、また、被成形物（５）をプレス機下部（７）にそれぞれセットし金型で樹脂をプレスすることによって、金型のキャビティ部（２）に樹脂が取り込まれ、金型の成形面の微細凹形状および／または微細凸形状が転写され、微細凸形状および／または微細凹形状を持った成形品が成形される。この時、金型に図１〜図３のような形状の金型を用いると、それぞれ図５〜図７のような形状の成形品が成形される。
ここで、図５〜図７に示すように、成形品について、金型の基準面により形成された面を成形品の基準面（２３）とし、この基準面からみた凹凸関係により形成された微細形状を微細凹形状或いは微細凸形状と区別する。成形時に正確な転写が行われないと、金型の微細凹形状の深さ（３）および／または微細凸形状の高さ（１５）および／または微細凸形状と土手の間に形成される凹形状の深さ（１７）と、それぞれ成形品の微細凸形状の高さ（１２）および／または微細凹形状の深さ（１８）および／または成形品の端部の凸形状の高さ（２０）は等しくならない。
1-3 is a figure which shows a metal mold | die (4), FIG. 4 is a figure which shows a mode that it shape | molds into a to-be-molded object using a press, and FIGS. 5-7 are FIGS. 1-3, respectively. It is a figure showing the molded article (11) obtained by shape | molding using a metal mold | die.
As shown in FIGS. 1 to 3, a bank (10) is formed around a fine concave shape portion and / or fine convex shape having a high aspect ratio on the molding surface of the mold. Here, on the molding surface of the mold, a smooth surface up to the bank around the fine convex shape and / or the fine concave shape portion is used as a reference surface (22) of the die, and the mold is determined by the unevenness viewed from the reference surface. The fine shape of the molding surface is a fine concave shape or a fine convex shape. As shown in FIG. 4, by pressing the resin with the mold by setting the mold (5) on the press machine upper part (6) used for molding and the molding object (5) on the press machine lower part (7), Resin is taken into the cavity portion (2) of the mold, the fine concave shape and / or fine convex shape of the molding surface of the mold is transferred, and a molded product having the fine convex shape and / or fine concave shape is molded. The At this time, if a mold having a shape as shown in FIGS. 1 to 3 is used as the mold, a molded product having a shape as shown in FIGS. 5 to 7 is formed.
Here, as shown in FIGS. 5 to 7, for the molded product, the surface formed by the reference surface of the mold is used as the reference surface (23) of the molded product, and the fineness formed by the concavo-convex relationship viewed from this reference surface. The shape is distinguished from a fine concave shape or a fine convex shape. If accurate transfer is not performed at the time of molding, the depth (3) and / or the height (15) of the fine convex shape of the mold and / or the concave formed between the fine convex shape and the bank are not formed. Depth of shape (17), height of fine convex shape (12) and / or depth of fine concave shape (18) and / or convex height of end of molded product (20 ) Are not equal.
金型の微細凹形状のアスペクト比は、図１、図３に示したように［金型の微細凹形状の深さ（３）／金型の微細凹形状の幅（１）］で、金型の隣接した微細凸形状間に形成される凹形状のアスペクト比は、図２、図３に示したように［金型の微細凸形状の高さ（１５）／金型の微細凸形状の間隔（１４）］で、金型の微細凸形状と土手により形成される凹形状のアスペクト比は、図３に［金型の微細凸形状と土手により形成される凹形状の深さ（１７）／金型の微細凸形状と土手により形成される凹形状の幅（１６）］で表される。
また、成形体の微細凸形状のアスペクト比は、図５、図７に示したように［成形体の微細凸形状の高さ（１２）／成形体の微細凸形状の幅（１３）］で、成形体の隣接した微細凹形状間に形成される凸形状のアスペクト比は、図６、図７に示したように［成形体の凹形状の深さ（１８）／成形体の凹形状の間隔（１９）］で、図６成形体の微細凹形状と成形品側面で形成される凸形状のアスペクト比は、［成形体端部の微細凸形状の高さ（２０）／成形体端部の微細凹形状の幅（２１）］で表される。
As shown in FIGS. 1 and 3, the aspect ratio of the fine concave shape of the mold is [the depth of the fine concave shape of the mold (3) / the width of the fine concave shape of the mold (1)]. As shown in FIG. 2 and FIG. 3, the aspect ratio of the concave shape formed between adjacent fine convex shapes of the mold is [the height of the fine convex shape of the mold (15) / the fine convex shape of the mold. In the interval (14)], the aspect ratio of the concave shape formed by the fine convex shape of the mold and the bank is shown in FIG. 3 [depth of the concave shape formed by the fine convex shape of the mold and the bank (17)]. / The width of the concave shape formed by the fine convex shape of the mold and the bank (16)].
Further, the aspect ratio of the fine convex shape of the molded product is [the height of the fine convex shape of the molded product (12) / the width of the fine convex shape of the molded product (13)] as shown in FIGS. As shown in FIGS. 6 and 7, the aspect ratio of the convex shape formed between the adjacent fine concave shapes of the molded body is [the depth of the concave shape of the molded body (18) / the concave shape of the molded body. In the interval (19)], the aspect ratio of the fine concave shape of the molded body shown in FIG. 6 and the convex shape formed on the side surface of the molded product is [the height (20) of the fine convex shape at the edge of the molded body / the edge of the molded body]. The width of the fine concave shape (21)].
金型（４）の成形面の高アスペクト比の微細凹形状部および／または微細凸形状部の周りの土手（１０）は、成形の際に樹脂が金型（４）の微細凹形状部および／または微細凸形状部に浸透せずに金型（４）の側面に逃げることを抑制するために形成するものである。良好な成形を行うためには、この土手の高さ（８）は、成形面に微細凹形状のみを有する金型の時にはその微細凹形状の最大の深さ以上の、成形面に微細凸形状のみを有する金型の時にはその微細凸形状の最大の高さの２倍以上の、成形面に微細凹形状かつ微細凸形状を有する時には最大の深さと最大の高さの２倍との和以上の土手を形成する必要がある。土手の高さがこれらの条件未満の場合、樹脂が微細凹形状部および／または微細凸形状部に浸透せずに金型（４）の側面に逃げることを十分に抑制できないため、完全な転写を行えないためである。 The fine concave shape portion having a high aspect ratio on the molding surface of the mold (4) and / or the bank (10) around the fine convex shape portion is formed of the fine concave shape portion of the mold (4) and the resin during molding. It is formed in order to suppress escape to the side surface of the mold (4) without penetrating into the fine convex portion. In order to perform good molding, the height (8) of the bank is a fine convex shape on the molding surface that is not less than the maximum depth of the fine concave shape in the case of a mold having only a fine concave shape on the molding surface. More than twice the maximum height of the fine convex shape in the case of a mold having only the shape, and more than the sum of the maximum depth and twice the maximum height when the molding surface has a fine concave shape and fine convex shape Need to form a bank. If the height of the bank is less than these conditions, it is not possible to sufficiently prevent the resin from escaping to the side surface of the mold (4) without penetrating into the fine concave portion and / or fine convex portion. This is because it cannot be performed.
被成形物の厚み（９）は金型の土手の高さより大きい必要がある。さらに厳密に言えば、被成形物の体積量は、金型（４）のキャビティ部を満たし、さらに土手（１０）の周りにはみ出すようにする必要がある。実際には被成形物は金型の土手により鋭利には切断されないので、はみ出す被成形物は金型キャビティ部の２割以上となることが望ましい。 The thickness (9) of the object to be molded needs to be larger than the height of the mold bank. Strictly speaking, it is necessary that the volume of the object to be molded fills the cavity of the mold (4) and protrudes around the bank (10). Actually, since the molding object is not sharply cut by the bank of the mold, it is desirable that the molding object that protrudes is 20% or more of the mold cavity portion.
本願発明の製造方法で用いる金型の材質は、微細凹形状部および／または微細凸形状部が成形時の負荷に耐え得るために超硬、鋼、ニッケルなどの金属材料或いは窒化ケイ素、サイアロン、炭化ケイ素、ＧＣ（グラッシーカーボン）などのセラミックス材料、または、これらを主成分とした複合体のいずれかであることが望ましい。また、成形時に金型の被成形物と接する部分には必要に応じて、離型性の向上のために成形面にＤＬＣ（ダイヤモンドライクカーボン）などのコーディング層を形成してもよいが、このコーティング層はガラスとの離型性を促進するものであればＤＬＣに限らない。また、微細凹形状部および／または微細凸形状部が上記材料で構成されていれば、その他の部分が成形時の温度、プレス圧力に耐えられる他の材料で構成されていてもよい。 The material of the mold used in the production method of the present invention is a metal material such as carbide, steel, nickel, silicon nitride, sialon, or the like so that the fine concave portion and / or the fine convex portion can withstand the load during molding. A ceramic material such as silicon carbide or GC (glassy carbon) or a composite containing these as a main component is desirable. In addition, a coating layer such as DLC (diamond-like carbon) may be formed on the molding surface as needed in order to improve releasability at the part of the mold that comes into contact with the molding object. The coating layer is not limited to DLC as long as it promotes releasability from glass. In addition, as long as the fine concave shape portion and / or the fine convex shape portion are made of the above-described material, the other portions may be made of other materials that can withstand the molding temperature and press pressure.
この製造方法で用いる被成形物の材質としては、メタクリル樹脂など一般的に成形に用いられる熱可塑性樹脂、或いはガラスであればよく、高アスペクト比の微細凸形状および／または微細凹形状を成形するために特別に成形温度における粘度を調整した材料である必要はない。 The material of the molding used in this manufacturing method may be a thermoplastic resin or glass generally used for molding, such as methacrylic resin, and molds a fine convex shape and / or a fine concave shape with a high aspect ratio. Therefore, it is not necessary to use a material whose viscosity at the molding temperature is specially adjusted.
次に、実施例に基づいて本発明を具体的に説明するが、本発明は、以下の実施例によって何ら制限されるものではない。 Next, the present invention will be specifically described based on examples, but the present invention is not limited to the following examples.
［実施例１］
図１に示すような形状で成形部に基準面に対し幅が１０μｍ、深さが２５μｍの微細凹形状が加工され、その周りに高さ２５μｍの土手を形成した超硬製の金型を図２に示すプレス機上部（６）にセットし、また、被成形物として３０μｍ厚のメタクリル樹脂（分子量１６００００）をプレス機下部にセットした。金型を１４０℃まで加熱してから加圧して、プレスを５分間行った。その後、空冷により９０℃まで降温させてから水冷により４０℃まで冷却した。金型からの樹脂の離型は、樹脂の成形面と反対の面を真空チャックにより固定して、金型をゆっくり引きはがすことにより行った。
[Example 1]
1 shows a cemented carbide mold in which a fine concave shape with a width of 10 μm and a depth of 25 μm is machined in the molded part and a bank with a height of 25 μm is formed around the molded part as shown in FIG. The methacrylic resin (molecular weight 160000) with a thickness of 30 μm was set at the lower part of the press machine as a molding. The mold was heated to 140 ° C. and then pressed and pressed for 5 minutes. Thereafter, the temperature was lowered to 90 ° C. by air cooling, and then cooled to 40 ° C. by water cooling. Release of the resin from the mold was performed by fixing the surface opposite to the resin molding surface with a vacuum chuck and slowly peeling the mold.
得られた樹脂成形品の成形部について顕微鏡による観察を実施したところ、樹脂の成形部には金型に加工した微細凹形状が完全に転写された微細凸形状が形成されていた。 When the molded portion of the obtained resin molded product was observed with a microscope, a fine convex shape in which the fine concave shape processed into the mold was completely transferred was formed in the resin molded portion.
［実施例２〜１６］
実施例２〜１６として、図１の形状の超硬製金型の成形部の微細凹形状の幅、深さと土手の高さ、成形するメタクリル樹脂の厚みを表１に示すように変えて、実施例１と同様の手順で成形試験を行った。結果は表１の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凹形状の深さと、成形品の微細凸形状の高さが等しくなり、金型の微細凹形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状が完全に転写されていないことを示す。実施例２〜１６ついては、表１に示すようにいずれの場合も金型に加工した微細凹形状は完全に転写されていた。
[Examples 2 to 16]
As Examples 2 to 16, the width, depth and height of the bank of the molded part of the cemented carbide mold having the shape of FIG. 1 and the thickness of the methacrylic resin to be molded are changed as shown in Table 1, A molding test was performed in the same procedure as in Example 1. The results are shown in the implementation result column of Table 1 with a circle or a cross. Here, the ◯ mark indicates that the depth of the fine concave shape of the mold is equal to the height of the fine convex shape of the molded product, and the fine concave shape of the mold is completely transferred. Are not equal, indicating that the fine concave shape of the mold is not completely transferred. For Examples 2 to 16, as shown in Table 1, in each case, the fine concave shape processed into the mold was completely transferred.
［比較例１〜８］
比較例１〜８として表２に示すように図９の形状の超硬製金型の成形部の微細凹形状の幅、深さ、被成形物となるメタクリル樹脂の厚みがそれぞれ実施例１〜８と同じで、土手が形成されていない金型を用いて、実施例１と同様の手順で成形を行った。結果は、表２の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凹形状の深さと、成形品の微細凸形状の高さが等しくなり、金型の微細凹形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状が完全に転写されていないことを示す。この場合、樹脂に転写された凸形状の高さは金型の凹形状の深さに満たず、金型に加工した微細凹形状は完全に転写されてはいなかった。
[Comparative Examples 1-8]
As shown in Table 2 as Comparative Examples 1 to 8, the width and depth of the fine concave shape of the molded part of the cemented carbide mold having the shape shown in FIG. The molding was performed in the same procedure as in Example 1 using the same mold as that in FIG. The results are shown in the implementation result column of Table 2 with ◯ marks or X marks. Here, the ◯ mark indicates that the depth of the fine concave shape of the mold is equal to the height of the fine convex shape of the molded product, and the fine concave shape of the mold is completely transferred. Are not equal, indicating that the fine concave shape of the mold is not completely transferred. In this case, the height of the convex shape transferred to the resin was less than the depth of the concave shape of the mold, and the fine concave shape processed into the mold was not completely transferred.
［実施例１７〜２０］
実施例１７〜２０として、図２に示すような成形部に微細凸形状と土手を形成した超硬製金型を用いたメタクリル樹脂への成形テストを表３に示す条件で被成形体に、実施例１と同様にして行った。結果は表３の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凸形状の高さおよび微細凸形状と土手の間に形成される凹形状の深さと、それぞれ対応する微細凹形状の深さおよび／または成形品の端部の凸形状の高さが等しくなり、金型の微細凸形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凸形状微細が完全に転写されていないことを示す。この場合、いずれの場合にも良好な成形が行われた。
[Examples 17 to 20]
As Examples 17 to 20, a molding test on a methacrylic resin using a cemented carbide mold in which a fine convex shape and a bank are formed on a molding portion as shown in FIG. The same operation as in Example 1 was performed. The results are shown in the implementation result column of Table 3 with ◯ marks or X marks. Here, the circles indicate the height of the fine convex shape of the mold and the depth of the concave shape formed between the fine convex shape and the bank, and the corresponding depth of the fine concave shape and / or the end of the molded product. The height of the convex shape of the mold is equal, indicating that the fine convex shape of the mold is completely transferred, and the x mark is not equal and the fine convex shape of the mold is completely transferred Indicates no. In this case, good molding was performed in any case.
［実施例２１〜２４］
実施例２１〜２４として、図８に示すような成形部に微細凹形状と微細凸形状と土手を形成した超硬製金型を用いたメタクリル樹脂への成形テストを表４に示す条件で、実施例１と同様にして行った。結果は表４の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凹形状の深さおよび／または微細凸形状の高さおよび／または微細凸形状と土手の間に形成される凹形状の深さと、それぞれ対応する成形品の微細凸形状の高さおよび／または微細凹形状の深さおよび／または成形品の端部の凸形状の高さが等しくなり金型の微細凹形状および／または微細凸形状微細が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状および／または微細凸形状微細が完全に転写されていないことを示す。この場合、いずれの場合にも良好な成形が行われた。
[Examples 21 to 24]
As Examples 21-24, the molding test to the methacryl resin using the super hard metal mold | die which formed the fine concave shape, the fine convex shape, and the bank in the shaping | molding part as shown in FIG. The same operation as in Example 1 was performed. The results are shown in the implementation result column of Table 4 with a circle or a cross. Here, the circles indicate the depth of the fine concave shape of the mold and / or the height of the fine convex shape and / or the depth of the concave shape formed between the fine convex shape and the bank, and the corresponding molded product. The height of the fine convex shape and / or the depth of the fine concave shape and / or the height of the convex shape at the end of the molded product are equal, and the fine concave shape and / or fine convex shape of the mold is completely transferred. The crosses indicate that they are not equal and the fine concave shape and / or fine convex shape fineness of the mold is not completely transferred. In this case, good molding was performed in any case.
［実施例２５〜３０］
表５に示すように金型の材質を変えてその他の条件を実施例１６と同様の条件の成形テストを行った。結果は表５の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凹形状の深さと、成形品の微細凸形状の高さが等しくなり、金型の微細凹形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状が完全に転写されていないことを示す。この場合、いずれの場合にも良好な成形が行われた。
[Examples 25 to 30]
As shown in Table 5, a molding test was performed under the same conditions as in Example 16 except that the material of the mold was changed. The results are shown in the implementation result column of Table 5 with a circle or a cross. Here, the ◯ mark indicates that the depth of the fine concave shape of the mold is equal to the height of the fine convex shape of the molded product, and the fine concave shape of the mold is completely transferred. Are not equal, indicating that the fine concave shape of the mold is not completely transferred. In this case, good molding was performed in any case.
［実施例３１］
実施例３１として、図１に示すような形状で成形部に基準面に対し幅が１０μｍ、深さが２５μｍの微細凹形状が加工され、その周りに高さ２５μｍの土手を形成し、成形時に被成形物と接する部分にＤＬＣコーティングをした超硬製の金型を図２に示すプレス機上部（６）にセットし、また、被成形物として３０μｍ厚のパイレックス（登録商標）ガラスをプレス機下部にセットした。金型を６８０℃まで加熱してから加圧して、プレスを５分間行った。その後、空冷により６０℃まで冷却した。金型からの成形品の離型は、パイレックス（登録商標）ガラスの成形面と反対の面を真空チャックにより固定して、金型をゆっくり引きはがすことにより行った。その結果、金型に加工した微細凹形状は完全に転写されていた。
[Example 31]
As Example 31, in the shape as shown in FIG. 1, a fine concave shape having a width of 10 μm and a depth of 25 μm with respect to the reference surface is processed in the molded part, and a bank with a height of 25 μm is formed around it. A cemented carbide die with DLC coating on the part in contact with the workpiece is set on the upper part (6) of the press shown in FIG. 2, and Pyrex (registered trademark) glass having a thickness of 30 μm is used as the molding machine. Set at the bottom. The mold was heated to 680 ° C. and then pressed and pressed for 5 minutes. Then, it cooled to 60 degreeC by air cooling. Release of the molded product from the mold was performed by fixing the surface opposite to the Pyrex (registered trademark) glass molding surface with a vacuum chuck and slowly peeling the mold. As a result, the fine concave shape processed into the mold was completely transferred.
［実施例３２〜４６］
実施例３２〜４６として、図１の形状で成形時に被成形物と接する部分にＤＬＣコーティングをした超硬製金型の成形部の微細凹形状の幅、深さと土手の高さ、成形するパイレックス（登録商標）ガラスの厚みを表６に示すように変えて、実施例３１と同様の手順で成形試験を行った。結果は、表６の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凹形状の深さと、成形品の微細凸形状の高さが等しくなり、金型の微細凹形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状が完全に転写されていないことを示す。実施例３２〜４６ついては、表６に示すようにいずれの場合も金型に加工した微細凹形状は完全に転写されていた。
[Examples 32-46]
As examples 32 to 46, the width, depth and height of the bank of the molded part of the cemented carbide mold in which the DLC coating is applied to the part in contact with the workpiece in the shape of FIG. The molding test was performed in the same procedure as in Example 31 with the thickness of (registered trademark) glass changed as shown in Table 6. The results are shown in the implementation result column of Table 6 with ◯ marks or X marks. Here, the ◯ mark indicates that the depth of the fine concave shape of the mold is equal to the height of the fine convex shape of the molded product, and the fine concave shape of the mold is completely transferred. Are not equal, indicating that the fine concave shape of the mold is not completely transferred. In Examples 32 to 46, as shown in Table 6, in each case, the fine concave shape processed into the mold was completely transferred.
［比較例９〜１６］
比較例９〜１６として表７に示すように図９の形状で成形時に被成形物と接する部分にＤＬＣコーティングをした超硬製金型の成形部の微細凹形状の幅、深さ、被成形物となるパイレックス（登録商標）ガラスの厚みがそれぞれ実施例３１〜３８と同じで、土手が形成されていない金型を用いて、実施例３１と同様の手順で成形を行った。結果は、表７の実施結果欄に○印或いは×印で示す。ここで○印は金型の微細凹形状の深さと、成形品の微細凸形状の高さが等しくなり、金型の微細凹形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状が完全に転写されていないことを示す。表７に示したようにいずれの場合もガラスに転写された微細凸形状は金型の微細凹形状が正確に転写されたものではなく、樹脂に転写された凸形状の高さは金型の凹形状の深さに満たないものであった。
[Comparative Examples 9 to 16]
As shown in Table 7 as Comparative Examples 9 to 16, the width and depth of the fine concave shape of the molded part of the cemented carbide mold in which the DLC coating is applied to the part in contact with the molded object in the shape of FIG. The thickness of the Pyrex (registered trademark) glass as the product was the same as in Examples 31 to 38, and molding was performed in the same procedure as in Example 31 using a mold in which no bank was formed. The results are shown in the implementation result column of Table 7 with ◯ marks or X marks. Here, the ◯ mark indicates that the depth of the fine concave shape of the mold is equal to the height of the fine convex shape of the molded product, and the fine concave shape of the mold is completely transferred. It is not equal, indicating that the fine concave shape of the mold is not completely transferred. As shown in Table 7, in any case, the fine convex shape transferred to the glass is not a precise transfer of the fine concave shape of the mold, and the height of the convex shape transferred to the resin is that of the mold. It was less than the depth of the concave shape.
［実施例４７〜５０］
実施例４７〜５０として、図２に示すような成形部に微細凸形状と土手を形成し、成形時に被成形物と接する部分にＤＬＣコーティングをした超硬製金型を用いたパイレックス（登録商標）ガラスへの成形テストを表８に示す条件で被成形体に、実施例３１と同様にして行った。結果は表８の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凸形状の高さおよび微細凸形状と土手の間に形成される凹形状の深さと、それぞれ対応する微細凹形状の深さおよび／または成形品の端部の凸形状の高さが等しくなり、金型の微細凸形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凸形状微細が完全に転写されていないことを示す。この場合、いずれの場合にも良好な成形が行われた。その結果、いずれの場合にも良好な成形が行われた。
[Examples 47 to 50]
As Examples 47 to 50, Pyrex (registered trademark) using a cemented carbide mold in which a fine convex shape and a bank are formed in a molded part as shown in FIG. 2 and DLC coating is applied to a part in contact with a molding object at the time of molding. ) A glass molding test was performed on the molded body in the same manner as in Example 31 under the conditions shown in Table 8. The results are shown in the implementation result column of Table 8 with a circle or a cross. Here, the circles indicate the height of the fine convex shape of the mold and the depth of the concave shape formed between the fine convex shape and the bank, and the corresponding depth of the fine concave shape and / or the end of the molded product. The height of the convex shape of the mold is equal, indicating that the fine convex shape of the mold is completely transferred, and the x mark is not equal and the fine convex shape of the mold is completely transferred Indicates no. In this case, good molding was performed in any case. As a result, good molding was performed in any case.
［実施例５１〜５４］
実施例５１〜５４として、図８に示すような成形部に微細凹形状と微細凸形状と土手を形成し成形時に被成形物と接する部分にＤＬＣコーティングをした超硬製金型を用いたパイレックス（登録商標）ガラスへの成形テストを表９に示す条件で、実施例３１と同様にして行った。結果は表９の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凹形状の深さおよび／または微細凸形状の高さおよび／または微細凸形状と土手の間に形成される凹形状の深さと、それぞれ対応する成形品の微細凸形状の高さおよび／または微細凹形状の深さおよび／または成形品の端部の凸形状の高さが等しくなり金型の微細凹形状および／または微細凸形状微細が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状および／または微細凸形状微細が完全に転写されていないことを示す。この場合、いずれの場合にも良好な成形が行われた。
[Examples 51 to 54]
As Examples 51 to 54, a Pyrex using a cemented carbide mold in which a fine concave shape, a fine convex shape, and a bank are formed in a molded portion as shown in FIG. A molding test for (registered trademark) glass was performed in the same manner as in Example 31 under the conditions shown in Table 9. The results are shown in the implementation result column of Table 9 with ◯ marks or X marks. Here, the circles indicate the depth of the fine concave shape of the mold and / or the height of the fine convex shape and / or the depth of the concave shape formed between the fine convex shape and the bank, and the corresponding molded product. The height of the fine convex shape and / or the depth of the fine concave shape and / or the height of the convex shape at the end of the molded product are equal, and the fine concave shape and / or fine convex shape of the mold is completely transferred. The crosses indicate that they are not equal and the fine concave shape and / or fine convex shape fineness of the mold is not completely transferred. In this case, good molding was performed in any case.
［実施例５５〜６０］
表１０に示すような材質で成形時に被成形物と接する部分にＤＬＣコーティングをした金型を用い、その他の条件を実施例４６と同様の条件で被成形物にパイレックス（登録商標）ガラスを用いた成形テストを行った。結果は表１０の実施結果欄に○印或いは×印で示す。ここで、○印は金型の微細凹形状の深さと、成形品の微細凸形状の高さが等しくなり、金型の微細凹形状が完全に転写されていることを示し、×印はそれらが等しくなっておらず金型の微細凹形状が完全に転写されていないことを示す。この場合、いずれの場合にも良好な成形が行われた。
[Examples 55 to 60]
Using a die made of DLC coating on the part that comes into contact with the molded object at the time of molding with the materials shown in Table 10, Pyrex (registered trademark) glass was used for the molded article under the same conditions as in Example 46. A molding test was performed. The results are shown in the implementation result column of Table 10 with a circle or a cross. Here, the ◯ mark indicates that the depth of the fine concave shape of the mold is equal to the height of the fine convex shape of the molded product, and the fine concave shape of the mold is completely transferred. Are not equal, indicating that the fine concave shape of the mold is not completely transferred. In this case, good molding was performed in any case.
これらの結果をまとめると、成形面に微細凹形状および／または微細凸形状を有する金型を用いて被成形物をプレスすることにより被成形物の表面に高アスペクト比の微細凸形状および／または微細凹形状を有する成形品を製造する方法において、高さが成形面に微細凹形状のみを有する金型の時にはその微細凹形状の最大の深さ以上の、成形面に微細凸形状のみを有する金型の時にはその微細凸形状の最大の高さの２倍以上の、成形面に微細凹形状かつ微細凸形状を有する時には最大の深さと最大の高さの２倍との和以上の土手をその微細凹形状部および／または微細凸形状部の周りに形成した金型を用いることにより、アスペクト比が２より大きい微細凸形状および／または微細凹形状の成形を樹脂或いはガラスに対して容易に行うことができた。また、高さが成形面に微細凹形状のみを有する金型の時にはその微細凹形状の深さの３倍以上の、成形面に微細凸形状のみを有する金型の時にはその微細凸形状の高さの６倍以上の、成形面に微細凹形状かつ微細凸形状を有する時には深さと高さの２倍との和の３倍以上の土手をその微細凹形状部および／または微細凸形状部の周りに形成した金型を用いることにより、被成形物の金型の微細凹形状部および／または微細凸形状部への流れ込みが良くなり、より高アスペクト比の微細凹形状の良好な成形を行うことができた。 Summarizing these results, a high aspect ratio fine convex shape and / or a high aspect ratio is formed on the surface of the molding by pressing the molding using a mold having a fine concave shape and / or a fine convex shape on the molding surface. In a method of manufacturing a molded product having a fine concave shape, when the mold has a height only with a fine concave shape on the molding surface, the molding surface has only the fine convex shape on the molding surface, which is not less than the maximum depth of the fine concave shape When the mold has a fine convex shape more than twice the maximum height, and when the molding surface has a fine concave shape and a fine convex shape, the bank should be more than the sum of the maximum depth and double the maximum height. By using a mold formed around the fine concave portion and / or fine convex shape portion, molding of the fine convex shape and / or fine concave shape having an aspect ratio larger than 2 can be easily performed on resin or glass. To do It could be. In addition, when the mold has only a fine concave shape on the molding surface, the height of the fine convex shape is higher than three times the depth of the fine concave shape, and when the mold has only a fine convex shape on the molding surface. When the molding surface has a fine concave shape and a fine convex shape that is 6 times or more of the height, the bank of 3 times or more of the sum of the depth and the height is twice or more of the fine concave shape portion and / or the fine convex shape portion. By using the mold formed around, the flow of the molding object into the fine concave shape portion and / or the fine convex shape portion of the mold can be improved, and the fine concave shape with a higher aspect ratio can be molded well. I was able to.
本発明の成形品の製造方法は、樹脂の片面に高アスペクト比の微細凸形状および／または微細凹形状を容易に製造することができるので、ＣＤ、ＤＶＤ等の成形品等の製造に特に好適に使用することができる。 The method for producing a molded product of the present invention is particularly suitable for the production of molded products such as CDs and DVDs because a high convexity and / or fine concave shape with a high aspect ratio can be easily produced on one side of the resin. Can be used for
１：金型の微細凹形状の幅
２：金型キャビティ部
３：金型の微細凹形状の深さ
４：金型
５：被成形物
６：成形に用いるプレス機上部
７：成形に用いるプレス機下部
８：金型の土手の高さ
９：被成形物の厚み
１０：金型の土手
１１：成形品
１２：成形品の微細凸形状の高さ
１３：成形品の微細凸形状の幅
１４：金型の微細凸形状の間隔
１５：金型の微細凸形状の高さ
１６：金型の微細凸形状と土手により形成される凹形状の幅
１７：金型の微細凸形状と土手により形成される凹形状の深さ
１８：成形体の微細凹形状の深さ
１９：成形体の微細凹形状の間隔
２０：成形体の端部の微細凸形状の高さ
２１：成形体の端部の微細凸形状の幅
２２：金型の成形面における基準面
２３：成形品の基準面
1: Width of fine concave shape of mold 2: Mold cavity portion 3: Depth of fine concave shape of mold 4: Mold 5: Molded object 6: Upper part of press used for molding 7: Press used for molding Lower part of machine 8: Height of mold bank 9: Thickness of molded object 10: Mold bank 11: Molded article 12: Height of minute convex shape of molded article 13: Width of minute convex shape of molded article 14 :
Claims (12)
Priority Applications (1)
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|---|---|---|---|
| JP2004367677A JP2006168314A (en) | 2004-12-20 | 2004-12-20 | Molded article having fine protrusion shape and/or fine recess shape, its manufacturing method and mold |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004367677A JP2006168314A (en) | 2004-12-20 | 2004-12-20 | Molded article having fine protrusion shape and/or fine recess shape, its manufacturing method and mold |
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| Publication Number | Publication Date |
|---|---|
| JP2006168314A true JP2006168314A (en) | 2006-06-29 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPWO2011007720A1 (en) * | 2009-07-14 | 2012-12-27 | 三菱レイヨン株式会社 | Punching acrylic film, surface light source device and optical member manufacturing method |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPWO2011007720A1 (en) * | 2009-07-14 | 2012-12-27 | 三菱レイヨン株式会社 | Punching acrylic film, surface light source device and optical member manufacturing method |
| JP5732852B2 (en) * | 2009-07-14 | 2015-06-10 | 三菱レイヨン株式会社 | Punching acrylic film, surface light source device and optical member manufacturing method |
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