JPH10138275A - Injection molding method and optical component - Google Patents
Injection molding method and optical componentInfo
- Publication number
- JPH10138275A JPH10138275A JP29835596A JP29835596A JPH10138275A JP H10138275 A JPH10138275 A JP H10138275A JP 29835596 A JP29835596 A JP 29835596A JP 29835596 A JP29835596 A JP 29835596A JP H10138275 A JPH10138275 A JP H10138275A
- Authority
- JP
- Japan
- Prior art keywords
- mold
- injection molding
- resin
- molding method
- shape
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/37—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings
- B29C45/372—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings provided with means for marking or patterning, e.g. numbering articles
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1701—Component parts, details or accessories; Auxiliary operations using a particular environment during moulding, e.g. moisture-free or dust-free
-
- 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
- B29C43/52—Heating or cooling
- B29C2043/522—Heating or cooling selectively heating a part of the mould to achieve partial heating, differential heating
-
- 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
- B29C43/52—Heating or cooling
- B29C2043/527—Heating or cooling selectively cooling, e.g. locally, on the surface of the material
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1701—Component parts, details or accessories; Auxiliary operations using a particular environment during moulding, e.g. moisture-free or dust-free
- B29C2045/1702—Component parts, details or accessories; Auxiliary operations using a particular environment during moulding, e.g. moisture-free or dust-free dissolving or absorbing a fluid in the plastic material
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、透明樹脂を用いて
表面に微細な凹凸形状を施した成形品を射出成形する方
法に関する。特に、面照明光源用導光板等の光学部品の
成形に適する射出成形方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for injection-molding a molded article having a fine irregular surface on its surface using a transparent resin. In particular, the present invention relates to an injection molding method suitable for molding optical components such as a light guide plate for a surface illumination light source.
【０００２】[0002]
【従来の技術】各種透明樹脂の射出成形に於いては、ス
クリュー等を利用して透明樹脂を加熱溶融し、金型内へ
充填後、冷却固化して任意の形状の成形品を得る方法が
一般に用いられている。このような方法では、溶融した
透明樹脂が金型表面に接触すると、その接触面で透明樹
脂が急速に冷却され、透明樹脂の流動性が著しく低下す
るため、金型表面に施された微細な凹凸形状を成形品に
転写させる場合、充分な転写効果が得られない場合があ
る。2. Description of the Related Art In injection molding of various transparent resins, there is a method of heating and melting a transparent resin using a screw or the like, filling it into a mold, and then cooling and solidifying to obtain a molded article of an arbitrary shape. It is commonly used. In such a method, when the molten transparent resin comes into contact with the mold surface, the transparent resin is rapidly cooled at the contact surface, and the fluidity of the transparent resin is significantly reduced. When transferring the uneven shape to a molded product, a sufficient transfer effect may not be obtained.
【０００３】表面に微細な凹凸形状を有する成形品を射
出成形する方法に於いては、通常は射出圧力や保圧を高
くする、流動性の高い透明樹脂材料を用いる、金型温度
を高くする等の方法が用いられる。In a method of injection-molding a molded article having fine irregularities on the surface, usually, the injection pressure and holding pressure are increased, a transparent resin material having high fluidity is used, and the mold temperature is increased. And the like.
【０００４】[0004]
【発明が解決しようとする課題】しかし、射出圧力や保
圧を高めていくと、溶融した透明樹脂を充填する時の流
動抵抗、及び冷却時の固化速度の不均一性が大きくな
り、金型内部に生じる圧力分布によって成形品中の残留
応力が増加し、成形品の変形あるいは反り等が発生す
る。However, when the injection pressure and the holding pressure are increased, the flow resistance at the time of filling the molten transparent resin and the non-uniformity of the solidification rate at the time of cooling are increased. Due to the pressure distribution generated inside, the residual stress in the molded article increases, and the molded article is deformed or warped.
【０００５】また、形状が微細になるほど、射出圧力や
保圧のみを高めただけでは転写効果に限界があり、溶融
した透明樹脂が固化する前に微細凹凸部に入り込んで付
形させるために、更に射出速度を大きくする必要があ
る。但し、射出速度を大きくすると、溶融した透明樹脂
のせん断発熱によるシルバーストリークス、金型表面と
溶融した熱可塑性樹脂との摩擦抵抗によるジェッティン
グやフローマーク等の外観不良が発生する。In addition, as the shape becomes finer, the transfer effect is limited only by increasing the injection pressure or the holding pressure, and the molten transparent resin enters the fine irregularities before being solidified and is shaped. Further, it is necessary to increase the injection speed. However, when the injection speed is increased, appearance defects such as silver streaks due to shear heating of the molten transparent resin and jetting and flow marks due to frictional resistance between the mold surface and the molten thermoplastic resin occur.
【０００６】流動性の高い透明樹脂を用いる場合、通常
は分子量を低下させて流動性を高める方法が採用され、
微細な凹凸形状を転写させる効果は得られるが、成形品
の機械的強度が低下し、高温高湿下や溶剤に接触する環
境下でクラック、クレージング等が発生するといった問
題が生じる。When a transparent resin having a high fluidity is used, a method of decreasing the molecular weight and increasing the fluidity is usually employed,
Although the effect of transferring the fine unevenness is obtained, the mechanical strength of the molded article is reduced, and problems such as generation of cracks and crazing under high temperature and high humidity or in an environment in contact with a solvent occur.
【０００７】金型温度を高くする事は、表面に微細な凹
凸形状を転写させる有効な手段であるが、金型の表面を
ＪＩＳＫ−７２０７法で規定された透明樹脂の荷重たわ
み温度以上に保持したまま成形品を金型から離型し取り
出す事は不可能である。成形品を金型から離型し取り出
すためには、使用する透明樹脂の荷重たわみ温度より低
い温度まで冷却固化する必要があるが、射出成形に用い
る金型は重量、容量ともに成形品形状よりも何倍も大き
い鋼鉄製のものが一般的であり、熱媒及び冷媒を交互に
循環させ加熱、冷却を繰り返すためには多くの熱量と時
間を必要とし、工業的に安定に生産するには困難であ
る。Increasing the mold temperature is an effective means of transferring fine irregularities to the surface, but the mold surface is maintained at a temperature equal to or higher than the load deflection temperature of the transparent resin specified by JIS K-7207. It is impossible to release the molded product from the mold while removing it. In order to release and remove the molded product from the mold, it is necessary to cool and solidify it to a temperature lower than the load deflection temperature of the transparent resin to be used. It is generally made of steel that is many times larger, and it takes a lot of heat and time to alternately circulate the heating medium and the refrigerant and repeat heating and cooling. It is.
【０００８】また、転写させる凹凸形状が微細になるほ
ど樹脂を充填した時に金型キャビティ表面と充填された
樹脂との間の空気が排出されにくくなり、微細凹凸形状
が充分に転写されず、また光沢ムラやフローマーク等の
外観不良を招く場合がある。特に、面照明光源用導光
板、フレネルレンズ、レンチキュラーレンズ、記録用デ
ィスク、光拡散シート、プリズムシート等の光学部品に
於いては、非常に微細な形状の転写性が要求されてお
り、転写不良や外観不良は致命的な問題となる。Further, as the irregularities to be transferred become finer, the air between the mold cavity surface and the filled resin becomes more difficult to be exhausted when the resin is filled, and the fine irregularities are not sufficiently transferred. This may lead to poor appearance such as unevenness and flow marks. Particularly, optical components such as a light guide plate for a surface illumination light source, a Fresnel lens, a lenticular lens, a recording disk, a light diffusion sheet, and a prism sheet require transferability of a very fine shape, resulting in poor transfer. And poor appearance are fatal problems.
【０００９】本発明の目的は、透明樹脂を用いて、微細
な凹凸形状の転写性に優れた成形品を透明樹脂が本来持
つ物性を低下させず、外観不良や変形等を伴わずに工業
的に安定して生産する方法、及びその方法により成形さ
れる光学部品を提供する事にある。An object of the present invention is to provide a molded article excellent in transferability of fine irregularities by using a transparent resin without deteriorating the physical properties inherent in the transparent resin, and without causing an appearance defect or deformation. Another object of the present invention is to provide a method for stably producing an optical component and an optical component formed by the method.
【００１０】[0010]
【課題を解決するための手段】本発明者らは、上記課題
を解決するため鋭意検討した結果、金型キャビティに二
酸化炭素を特定の圧力で満たしておき射出成形する事に
より、金型表面の微細な凹凸形状が充分に転写され外観
不良のない成形品が得られる事を見出し、本発明を完成
した。Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above-mentioned problems, and as a result, the mold cavity has been filled with carbon dioxide at a specific pressure and injection-molded, whereby the surface of the mold has been reduced. The present inventors have found that a molded article free from poor appearance can be obtained by transferring the fine irregularities sufficiently, and completed the present invention.
【００１１】即ち本発明は、透明樹脂を用いて、少なく
とも一方の面に微細な凹凸形状が付与された成形品を射
出成形する方法に於いて、金型キャビティに二酸化炭素
を１０ＭＰａ以下の圧力で満たしておき射出成形する事
を特徴とする射出成形方法及び該射出成形方法により得
られる光学部品である。That is, the present invention relates to a method for injection-molding a molded article having a fine unevenness on at least one surface using a transparent resin, wherein carbon dioxide is injected into a mold cavity at a pressure of 10 MPa or less. An injection molding method characterized by satisfying injection molding, and an optical component obtained by the injection molding method.
【００１２】本発明は、従来、溶融した樹脂の充填によ
り高温圧縮されて樹脂の酸化劣化をもたらし、また金型
表面形状の転写を阻害すると考えられていた金型キャビ
ティ内の空気を特定のガスで置換しておく点に着目した
ものである。According to the present invention, the air inside the mold cavity, which has conventionally been considered to be oxidized and degraded by filling the molten resin at a high temperature to cause the resin to oxidize and degrade the surface shape of the mold, is removed by a specific gas. It focuses on the point of replacing with.
【００１３】即ち、金型キャビティ内に二酸化炭素を封
入しておく事で、溶融樹脂が充填され二酸化炭素が高温
圧縮されても、樹脂への溶解性が高いために樹脂中へ溶
け込み、酸化劣化を引き起こす事がない。また、金型キ
ャビティへ充填された溶融樹脂の表面付近で二酸化炭素
が樹脂へ溶解する事で、溶融した樹脂の固化温度が下が
り金型表面での樹脂の急激な粘度上昇を抑えられるた
め、金型表面の凹凸形状の細部にまで樹脂が流動して付
形され、転写性が向上する。That is, by filling carbon dioxide in the mold cavity, even if the molten resin is filled and carbon dioxide is compressed at a high temperature, it is dissolved into the resin because of its high solubility in the resin, and is oxidized and deteriorated. Never cause. In addition, since carbon dioxide dissolves in the resin near the surface of the molten resin filled in the mold cavity, the solidification temperature of the molten resin decreases, and a sharp increase in the viscosity of the resin on the mold surface can be suppressed. The resin flows to the details of the irregularities on the mold surface and is shaped, thereby improving transferability.
【００１４】また、溶融した樹脂の固化温度が下がる事
により、金型内部での流動性が良くなり、低い射出圧力
での成形が可能となるため、成形品の残留歪みを低減さ
せる事ができる。さらに、薄肉部が１ｍｍ以下であるよ
うな薄肉、偏肉形状の成形品の成形も可能となる。Further, since the solidification temperature of the molten resin is lowered, the fluidity inside the mold is improved, and molding at a low injection pressure becomes possible, so that the residual distortion of the molded product can be reduced. . Further, it is possible to form a thin-walled or uneven-walled molded product having a thin portion of 1 mm or less.
【００１５】[0015]
【発明の実施の形態】本発明に用いる二酸化炭素の圧力
は、各成形工程に使用するガス量を最小限に押さえ、金
型の気密性を持たせる構造やガス供給装置の構造を簡単
にできる点で、１０ＭＰａ以下である必要がある。好ま
しくは０．１ＭＰａ以上１０ＭＰａ以下、より好ましく
は１ＭＰａ以上１０ＭＰａ以下である。１０ＭＰａ以下
であれば、金型を開こうとする力を無視でき、また金型
の気密性が悪くなる等の問題が生じず、好ましい。DESCRIPTION OF THE PREFERRED EMBODIMENTS The pressure of carbon dioxide used in the present invention can minimize the amount of gas used in each molding step and can simplify the structure for providing airtightness of a mold and the structure of a gas supply device. In this respect, the pressure needs to be 10 MPa or less. Preferably it is 0.1 MPa or more and 10 MPa or less, more preferably 1 MPa or more and 10 MPa or less. When the pressure is 10 MPa or less, the force for opening the mold can be ignored, and problems such as deterioration of the airtightness of the mold do not occur.
【００１６】二酸化炭素は特に限定されないが、純度９
５％以上であることが好ましい。The carbon dioxide is not particularly limited, but has a purity of 9%.
It is preferably at least 5%.
【００１７】本発明で用いる金型の表面に施される微細
な凹凸形状は、特に限定されないが、例えば、構成単位
がプリズム形状、立方体形状、直方体形状、円筒形状、
楕円筒形状、球面状または非球面状であるもの、梨地状
等が挙げられる。The fine irregularities formed on the surface of the mold used in the present invention are not particularly limited. For example, the structural units may be prism-shaped, cubic, cuboid, cylindrical, and the like.
Examples include an elliptic cylinder, a spherical or aspherical surface, and a satin finish.
【００１８】構成単位がプリズム形状、立方体形状、直
方体形状、円筒形状、楕円筒形状、球面状または非球面
状である場合には、構成単位の形状の高さａと配列ピッ
チｂとの比ｂ／ａが０．２〜５００である事が好まし
い。より好ましくは１〜５０である。形状の高さａと配
列ピッチｂは図１に示す様に定義する。即ち、形状の高
さａとは、構成単位の最大高さを、配列ピッチｂとは、
隣り合う構成単位の中心線間の長さをいう。ｂ／ａが
０．２〜５００の範囲内にあれば、形状の高さａと配列
ピッチｂは、縦又は横方向で任意に変化しても良い。When the structural unit is prismatic, cubic, rectangular, cylindrical, elliptical, spherical or aspherical, the ratio b between the height a of the structural unit and the arrangement pitch b / A is preferably from 0.2 to 500. More preferably, it is 1 to 50. The height a of the shape and the arrangement pitch b are defined as shown in FIG. That is, the height a of the shape is the maximum height of the structural unit, and the arrangement pitch b is
It means the length between the center lines of adjacent constituent units. If b / a is in the range of 0.2 to 500, the shape height a and the arrangement pitch b may be arbitrarily changed in the vertical or horizontal direction.
【００１９】これらの形状の配列は、例えばドット状、
直線状、曲線状の何れでも良い。また、凹凸形状の高さ
と配列されている間隔は、縦又は横方向で任意に変化し
ても良い。尚、微細な凹凸形状は市販の光学顕微鏡又は
電子顕微鏡により観察する事ができる。The arrangement of these shapes is, for example, a dot shape,
Any of a linear shape and a curved shape may be used. In addition, the height of the uneven shape and the interval of the arrangement may be arbitrarily changed in the vertical or horizontal direction. Incidentally, the fine irregularities can be observed with a commercially available optical microscope or electron microscope.
【００２０】また、梨地状である場合には、ＪＩＳ Ｂ
０６０１−１９９４法により測定した表面粗さの最大高
さ（Ｒｙ）が１〜１００μｍの範囲にある事が好まし
い。より好ましくは１〜５０μｍである。尚、梨地状面
の表面粗さは、市販の表面粗さ計を用いて測定する事が
できる。In the case of a satin finish, JIS B
The maximum height (Ry) of the surface roughness measured by the 0601-1994 method is preferably in the range of 1 to 100 μm. More preferably, it is 1 to 50 μm. The surface roughness of the satin-like surface can be measured using a commercially available surface roughness meter.
【００２１】本発明に用いられる透明樹脂は、特に限定
されないが、ＪＩＳＫ−７１０５に準じて測定したヘー
ズが１０％以下となる物質が好ましい。具体的にはメタ
クリル樹脂、ポリカーボネート樹脂、ポリスチレン樹
脂、スチレン−メチルメタクリレート共重合樹脂、スチ
レン−ブタジエン共重合樹脂、非晶質ポリオレフィン樹
脂、ポリ塩化ビニル樹脂等が挙げられる。好ましく採用
されるものは、メタクリル樹脂、ポリカーボネート樹脂
である。特に好ましく採用されるものは、メタクリル樹
脂である。The transparent resin used in the present invention is not particularly limited, but is preferably a substance having a haze of 10% or less as measured according to JIS K-7105. Specific examples include methacrylic resin, polycarbonate resin, polystyrene resin, styrene-methyl methacrylate copolymer resin, styrene-butadiene copolymer resin, amorphous polyolefin resin, polyvinyl chloride resin and the like. Those preferably employed are methacrylic resins and polycarbonate resins. Particularly preferred is a methacrylic resin.
【００２２】メタクリル樹脂としては、例えばメタクリ
ル酸メチルを主体とする樹脂が挙げられ、具体的にはメ
チルメタクリレートの単独重合体、又はメチルメタクリ
レートとメチルアクリレート、エチルアクリレート、ｎ
−プロピルアクリレート、イソプロピルアクリレート、
ブチルアクリレート、アクリロニトリル、アクリル酸、
メタクリル酸、ビニルピリジン、ビニルモルホリン、ビ
ニルピリドンテトラヒドロフルフリルアクリレート、
Ｎ，Ｎ−ジメチルアミノエチルアクリレート、Ｎ，Ｎ−
ジメチルアクリルアミド、２−ヒドロキシアクリレー
ト、エチレングリコールモノアクリレート、グリセリン
モノアクリレート、無水マレイン酸、スチレン、もしく
はα−メチルスチレンなどの共重合可能なモノマーのい
ずれか一つ以上との共重合体、及び耐熱性アクリル樹
脂、低吸湿性アクリル樹脂などが含まれる。これらは単
独で用いてもよいしブレンドしてもよい。Examples of the methacrylic resin include a resin mainly composed of methyl methacrylate. Specifically, a homopolymer of methyl methacrylate, or methyl methacrylate and methyl acrylate, ethyl acrylate, n
-Propyl acrylate, isopropyl acrylate,
Butyl acrylate, acrylonitrile, acrylic acid,
Methacrylic acid, vinyl pyridine, vinyl morpholine, vinyl pyridone tetrahydrofurfuryl acrylate,
N, N-dimethylaminoethyl acrylate, N, N-
A copolymer with any one or more copolymerizable monomers such as dimethylacrylamide, 2-hydroxyacrylate, ethylene glycol monoacrylate, glycerin monoacrylate, maleic anhydride, styrene, or α-methylstyrene, and heat resistance Acrylic resin, low hygroscopic acrylic resin and the like are included. These may be used alone or may be blended.
【００２３】透明性を維持して耐衝撃性を同時に持たせ
るためには耐衝撃性アクリル樹脂が用いられ、そのゴム
弾性体は特開昭５３−５８５５４号公報、同５５−９４
９１７号公報、同６１−３２３４６号公報等に開示され
ている。簡単に説明すると、アクリル系重合体芯材料の
まわりに弾性層及び非弾性層を交互に生成させる多段階
逐次重合法により製造される多段重合体である。In order to maintain transparency and provide impact resistance at the same time, an impact-resistant acrylic resin is used, and its rubber elastic body is disclosed in JP-A-53-55854 and JP-A-55-94.
Nos. 917 and 61-32346. Briefly, it is a multi-stage polymer produced by a multi-stage sequential polymerization method in which an elastic layer and an inelastic layer are alternately formed around an acrylic polymer core material.
【００２４】本発明の射出成形方法に於いては二酸化炭
素を使用するが、二酸化炭素は溶融樹脂表面に溶解し固
化してしまえば発泡現象を引き起こす事はない。また、
成形品表面中に溶け込んだ二酸化炭素は、成形品を取り
出した後、徐々に大気中に放散すると考えられるため、
危険性はない。In the injection molding method of the present invention, carbon dioxide is used. However, if the carbon dioxide is dissolved and solidified on the surface of the molten resin, it does not cause a foaming phenomenon. Also,
Since carbon dioxide dissolved in the surface of the molded product is considered to be gradually released into the atmosphere after removing the molded product,
There is no danger.
【００２５】本発明に於ける射出成形方法は、金型温度
を高く設定すれば低い二酸化炭素圧力で充分な転写効果
が得られる。金型温度の好ましい範囲は６０〜１００℃
である。In the injection molding method of the present invention, if the mold temperature is set high, a sufficient transfer effect can be obtained at a low carbon dioxide pressure. The preferable range of the mold temperature is 60 to 100 ° C.
It is.
【００２６】また本発明に於ける射出成形方法では、樹
脂の充填速度を変化させても金型表面形状の成形品への
転写状態は変化する事がないため、成形条件範囲が広が
る。本発明の射出成形方法は、特に光学部品の成形に好
適である。光学部品としては、例えば、表面に凹凸形状
が施された板状の面照明光源用導光板、フレネルレン
ズ、レンチキュラーレンズ、記録用ディスク、光拡散シ
ート、プリズムシート等が挙げられる。これらの部品の
厚みは特に限定されないが、好ましくは０．１〜１０ｍ
ｍ、更に好ましくは０．５〜５ｍｍである。In the injection molding method according to the present invention, the state of transfer of the mold surface shape to the molded product does not change even if the filling speed of the resin is changed, so that the range of molding conditions is widened. The injection molding method of the present invention is particularly suitable for molding optical components. Examples of the optical component include a plate-shaped light guide plate for a surface illumination light source, a Fresnel lens, a lenticular lens, a recording disk, a light diffusion sheet, a prism sheet, and the like, the surface of which has an uneven shape. The thickness of these parts is not particularly limited, but is preferably 0.1 to 10 m
m, more preferably 0.5 to 5 mm.
【００２７】特に、液晶表示装置等に用いられる面照明
光源は明るさに対する要求が高く、導光板表面に形成さ
れた凹凸部の配列の規則性や形状、大きさを変化させる
事により面照明光源の性能が決定されている。従って、
微細凹凸形状の転写性が高く輝度分布が一様で、外観不
良による輝点不良等がない導光板が望まれている。本発
明の射出成形方法により得られる面照明光源用導光板
は、微細凹凸形状の転写性が高いため発光効率が高く、
また外観不良による輝点不良等を防げるため良好な面照
明光源を得る事ができるため非常に好ましい。In particular, surface illumination light sources used in liquid crystal display devices and the like have a high demand for brightness, and the surface illumination light source is changed by changing the regularity, shape, and size of the arrangement of uneven portions formed on the surface of the light guide plate. Performance has been determined. Therefore,
There is a demand for a light guide plate that has a high transferability of fine irregularities and a uniform luminance distribution and is free from defective bright spots due to poor appearance. The light guide plate for a surface illumination light source obtained by the injection molding method of the present invention has high luminous efficiency due to high transferability of the fine irregularities,
In addition, it is very preferable because a good surface illumination light source can be obtained in order to prevent a defective bright spot due to poor appearance.
【００２８】[0028]
【実施例】以下、実施例、比較例で本発明を具体的に説
明する。なお、各実施例、比較例で用いた評価及び試験
方法は次の通りである。The present invention will be described below in detail with reference to examples and comparative examples. The evaluation and test methods used in each of the examples and comparative examples are as follows.
【００２９】（１）表面に微細凹凸形状を有する射出成
形品の作成 図２に示す様に、成形品中心に直径８ｍｍのダイレクト
ゲート１を設け、スプル２の長さは５８ｍｍ、ノズルタ
ッチ部３の直径を３．５ｍｍである金型（Ａ）を用い
た。金型のキャビティ外周にはガス供給と開放のための
深さ０．０５ｍｍのベントスリット４とベント５、およ
びベント５から金型外に通じるガス供給・排出孔６を設
けてガス供給装置と接続し、ベントスリット４とガス供
給・排出孔６の外周にガスシールのためにＯリング７を
設け、キャビティを気密構造とした。また、キャビティ
表面は鏡面部分８と梨地状面部分９を設けた。梨地状面
部分９のＪＩＳ Ｂ０６０１−１９９４法により測定し
た表面粗さの最大高さ（Ｒｙ）は１５μｍである。得ら
れる成形品は厚み２ｍｍで、縦横各１００ｍｍの正方形
平板である。(1) Preparation of an injection molded product having fine irregularities on the surface As shown in FIG. 2, a direct gate 1 having a diameter of 8 mm is provided at the center of the molded product, a sprue 2 has a length of 58 mm, and a nozzle touch portion 3 (A) having a diameter of 3.5 mm was used. A vent slit 4 and a vent 5 having a depth of 0.05 mm for gas supply and release are provided on the outer periphery of the cavity of the mold, and gas supply / discharge holes 6 communicating from the vent 5 to the outside of the mold are connected to a gas supply device. Then, an O-ring 7 was provided on the outer periphery of the vent slit 4 and the gas supply / discharge hole 6 for gas sealing, and the cavity had an airtight structure. Further, the cavity surface was provided with a mirror surface portion 8 and a satin surface portion 9. The maximum height (Ry) of the surface roughness of the satin-like surface portion 9 measured by the JIS B0601-1994 method is 15 μm. The obtained molded product is a square flat plate having a thickness of 2 mm and a length and width of 100 mm.
【００３０】また、同様の機密構造を持たせ、キャビテ
ィ表面に形状の高さａが３２μｍ、配列ピッチｂが１９
０〜７１０μｍの範囲で順次変化する直方体形状単位が
配列された金型（Ｂ）を準備した。得られる成形品は厚
肉部が２．５ｍｍ、薄肉部が１ｍｍである楔形で、縦１
５０ｍｍ、横１００ｍｍの長方形板である。Further, the same security structure is provided, and the height a of the shape is 32 μm and the arrangement pitch b is 19 μm on the cavity surface.
A mold (B) in which rectangular parallelepiped units sequentially changing in a range of 0 to 710 μm were prepared. The obtained molded product is a wedge shape having a thick portion of 2.5 mm and a thin portion of 1 mm, and has a length of 1 mm.
It is a rectangular plate of 50 mm and 100 mm in width.
【００３１】これら２種類の金型を成形機（住友重機械
工業製ＳＧ−１００）に取付け、成形温度を２４０℃に
設定し、透明樹脂としてメタクリル樹脂（旭化成工業製
デルペット８０ＮＨ）を用いて射出成形を行った。These two types of molds were mounted on a molding machine (SG-100 manufactured by Sumitomo Heavy Industries, Ltd.), the molding temperature was set to 240 ° C., and methacrylic resin (Delpet 80NH manufactured by Asahi Kasei Kogyo) was used as a transparent resin. Injection molding was performed.
【００３２】ガスは純度９９％以上の二酸化炭素、窒
素、及び圧縮空気を使用した。As the gas, carbon dioxide, nitrogen, and compressed air having a purity of 99% or more were used.
【００３３】（２）成形品の表面凹凸形状の転写率の測
定 上記（１）で用いた金型（Ａ）の表面、及び上記（１）
の方法で金型（Ａ）を用いて得た成形品の表面の粗さ
を、ＪＩＳ−Ｂ０６０１−１９９６に準じた表面粗さ計
（東京精密製サーフコム５７５Ａ型）で測定し、最大高
さ（Ｒｙ）を測定する。次式に従って、転写率を導出す
る。転写率＝（成形品のＲｙの値）／（金型表面のＲｙ
の値）(2) Measurement of transfer rate of surface unevenness of molded product Surface of mold (A) used in (1) and (1)
The surface roughness of the molded article obtained by using the mold (A) by the method described in (1) above was measured with a surface roughness meter (Surfcom 575A manufactured by Tokyo Seimitsu Co., Ltd.) according to JIS-B0601-1996, and the maximum height ( Ry) is measured. The transfer rate is derived according to the following equation. Transfer rate = (Ry value of molded product) / (Ry of mold surface)
The value of the)
【００３４】（３）全光線透過率、ヘーズの測定 上記（１）の方法で金型（Ａ）を用いて得た成形品につ
いて、ＪＩＳＫ−７１０５に準じたヘイズメーター（日
本電色工業製１００１−ＤＰ型）により全光線透過率、
ヘーズを測定する。(3) Measurement of Total Light Transmittance and Haze For the molded product obtained by using the mold (A) by the method (1), a haze meter (1001 manufactured by Nippon Denshoku Industries Co., Ltd.) according to JIS K-7105 is used. -DP type), the total light transmittance,
Measure haze.
【００３５】（４）６０度鏡面光沢度の測定 上記（１）の方法で金型（Ａ）を用いて得た成形品につ
いて、ＪＩＳＺ−８７４１法に準じたグロスチェッカ
（堀場製作所製ＩＧ−３１０型）により６０度鏡面光沢
度を測定する。(4) Measurement of 60 ° Specular Gloss The molded product obtained by using the mold (A) by the method of (1) above was subjected to a gross checker (IG-310 manufactured by Horiba, Ltd.) according to the JISZ-8741 method. 60) specular glossiness is measured by a mold.
【００３６】（５）面照明光源の輝度分布測定 図３に示す様に、上記（１）の方法で金型（Ｂ）を用い
て得た成形品１０の凹凸形状面に反射フィルム１１、反
対側の面に拡散フィルム１２を貼り付け、成形品１０の
厚肉部端面に冷陰極管１３（直径３ｍｍ、長さ２２０ｍ
ｍ）を配置しインバーターに接続して面光源照明装置を
作成した。冷陰極管１３を点灯後３０分間放置して明る
さを安定させた後、発光面の輝度を輝度計１４（ミノル
タカメラ社製ＣＡ−１０００型）で測定した。得られた
輝度分布に於いて、輝度平均値、及び輝度均斉度（輝度
最小値を輝度最大値で除した値）を導出した。(5) Measurement of Luminance Distribution of Surface Illumination Light Source As shown in FIG. 3, a reflective film 11 is formed on the uneven surface of the molded product 10 obtained by using the mold (B) by the method (1). The diffusion film 12 is adhered to the side surface, and the cold cathode tube 13 (diameter 3 mm, length 220 m
m) was arranged and connected to an inverter to create a surface light source lighting device. After the cold cathode tube 13 was turned on and left for 30 minutes to stabilize the brightness, the luminance of the light emitting surface was measured with a luminance meter 14 (model CA-1000 manufactured by Minolta Camera Co., Ltd.). In the obtained luminance distribution, a luminance average value and a luminance uniformity (a value obtained by dividing the minimum luminance value by the maximum luminance value) were derived.
【００３７】（実施例１〜３、比較例１〜５）金型
（Ａ）を用い、使用したガスの種類、圧力、及び金型温
度を表１に示す通りとして射出成形を行い、得られた成
形品を用いて上記（２）〜（４）の評価を行い、表２に
示す結果を得た。(Examples 1 to 3 and Comparative Examples 1 to 5) Injection molding was performed using the mold (A) with the type of gas used, pressure and mold temperature as shown in Table 1. The evaluation of the above (2) to (4) was performed using the molded article obtained, and the results shown in Table 2 were obtained.
【００３８】[0038]
【表１】 [Table 1]
【００３９】[0039]
【表２】 [Table 2]
【００４０】実施例１〜３では、転写率は０．７２〜
０．９０を示しいずれも比較例１に示した通常成形品に
対して転写性の向上効果が確認できた。微細形状の転写
性が向上した事により表面の光反射が増加し、全光線透
過率は８７〜９１％、６０度鏡面光沢度は３〜７と低
下、ヘーズは６６〜７３％と向上し非常に好ましい。In Examples 1 to 3, the transfer rate was 0.72 to 0.72.
In each case, the transferability was improved with respect to the normal molded product shown in Comparative Example 1. Due to the improved transferability of the fine shape, the light reflection on the surface increases, the total light transmittance decreases from 87 to 91%, the 60-degree specular gloss decreases from 3 to 7, and the haze increases from 66 to 73%. Preferred.
【００４１】比較例１では、ガスを使用せずに通常の射
出成形を行った。転写率は０．６７と充分ではなく、全
光線透過率は８７％、ヘーズは５５％、６０度鏡面光沢
度は１２であった。In Comparative Example 1, ordinary injection molding was performed without using gas. The transfer rate was not sufficient at 0.67, the total light transmittance was 87%, the haze was 55%, and the 60 ° specular gloss was 12.
【００４２】比較例２では、二酸化炭素を１５ＭＰａの
圧力で封入し射出成形を行った。金型の開きが生じるた
め、転写率は０．６８程度でほとんど効果がなかった。
また、全光線透過率は９２％、ヘーズは５６％、６０度
鏡面光沢度は１２であり通常成形とほぼ同等であり、好
ましくない結果となった。In Comparative Example 2, injection molding was performed with carbon dioxide sealed at a pressure of 15 MPa. Since the mold was opened, the transfer rate was about 0.68, and there was almost no effect.
Further, the total light transmittance was 92%, the haze was 56%, and the 60-degree specular gloss was 12, which was almost the same as that of ordinary molding, and was an undesirable result.
【００４３】比較例３〜５では、ガスに圧縮空気、窒素
を用いて射出成形を行った。金型内のガスは溶融樹脂へ
の溶解性を示さないため、最終充填前に樹脂が急冷され
てしまい、転写率は０．４２〜０．５と通常成形よりも
悪い結果となった。また、全光線透過率は９２％、ヘー
ズは４８〜５０％、６０度鏡面光沢度は１４〜１７であ
り通常成形よりも透明感があり、金型表面の微細形状が
充分に転写されておらず好ましくない結果となった。In Comparative Examples 3 to 5, injection molding was performed using compressed air and nitrogen as gas. Since the gas in the mold does not show solubility in the molten resin, the resin was quenched before the final filling, and the transfer rate was 0.42 to 0.5, which was worse than normal molding. Further, the total light transmittance is 92%, the haze is 48 to 50%, the 60-degree specular gloss is 14 to 17, which is more transparent than usual molding, and the fine shape of the mold surface is sufficiently transferred. The result was unfavorable.
【００４４】（実施例４〜５、比較例６〜７）金型
（Ｂ）を用い、使用したガスの種類、圧力、及び金型温
度を表３に示す通りとして射出成形を行い、得られた成
形品を用いて上記（５）の評価を行い、表４に示す結果
を得た。(Examples 4 and 5, Comparative Examples 6 and 7) Injection molding was performed using the mold (B) with the type of gas used, pressure and mold temperature as shown in Table 3. The evaluation of the above (5) was performed using the molded article obtained, and the results shown in Table 4 were obtained.
【００４５】[0045]
【表３】 [Table 3]
【００４６】[0046]
【表４】 [Table 4]
【００４７】実施例４〜５では、輝度平均値は５８０〜
６２０ｎｔ、輝度均斉度は０．６１〜０．６５と高い値
を示しを示し、均一で明るい面照明光源装置を得る事が
でき非常に好ましい結果となった。In Examples 4 and 5, the average luminance value was 580 to 580.
620 nt, the luminance uniformity showed a high value of 0.61 to 0.65, and a uniform and bright surface illumination light source device could be obtained, which was a very preferable result.
【００４８】比較例６〜７では、輝度平均値は３５０〜
４８０ｎｔ、輝度均斉度は０．３５〜０．４６と低い値
を示し、面照明光源装置として充分な性能が得られず好
ましくない結果となった。In Comparative Examples 6 and 7, the average luminance value was 350
At 480 nt, the luminance uniformity showed a low value of 0.35 to 0.46, which was not preferable because sufficient performance as a surface illumination light source device could not be obtained.
【００４９】[0049]
【発明の効果】本発明の射出成形方法により、微細な凹
凸形状の転写性に優れた成形品を、透明樹脂が本来持つ
物性を低下させず、外観不良や変形等を伴わずに工業的
に安定して生産する事ができる。Industrial Applicability According to the injection molding method of the present invention, a molded article excellent in transferability of fine irregularities can be produced industrially without deteriorating the physical properties inherent in the transparent resin and without causing poor appearance or deformation. It can be produced stably.
【図１】微細凹凸形状の構成単位の形状高さａと配列ピ
ッチｂの関係を示す図。FIG. 1 is a diagram showing a relationship between a configuration height a and an arrangement pitch b of constituent units of a fine uneven shape.
【図２】本実施例に用いた金型の概念図。FIG. 2 is a conceptual diagram of a mold used in the present embodiment.
【図３】本実施例に用いた面照明光源の輝度分布測定方
法の概念図。FIG. 3 is a conceptual diagram of a luminance distribution measuring method of a surface illumination light source used in the present embodiment.
１ ダイレクトゲート ２ スプル ３ ノズルタッチ部 ４ ベントスリット ５ ベント ６ ガス供給・排出孔 ７ Ｏリング ８ 鏡面部分 ９ 梨地状面部分 １０ 成形品 １１ 反射フィルム １２ 拡散フィルム １３ 冷陰極管 １４ 輝度計 DESCRIPTION OF SYMBOLS 1 Direct gate 2 Sprue 3 Nozzle touch part 4 Vent slit 5 Vent 6 Gas supply / discharge hole 7 O-ring 8 Mirror surface part 9 Satin surface part 10 Molded product 11 Reflection film 12 Diffusion film 13 Cold cathode tube 14
Claims (6)
状を施した金型を用いて少なくとも一方の面に該微細凹
凸形状が付与された成形品を射出成形する方法に於い
て、金型キャビティに二酸化炭素を１０ＭＰａ以下の圧
力で満たしておき射出成形する事を特徴とする射出成形
方法。In a method for injection-molding a molded article having a fine irregular shape on at least one surface using a mold having a fine irregular shape on a surface thereof using a transparent resin. An injection molding method characterized by filling a mold cavity with carbon dioxide at a pressure of 10 MPa or less and performing injection molding.
ａ以下の圧力で満たしておく事を特徴とする請求項１に
記載の射出成形方法。2. Carbon dioxide of 0.1 MPa or more and 10 MPa
2. The injection molding method according to claim 1, wherein the pressure is satisfied at a pressure equal to or less than a.
構成単位がプリズム形状、立方体形状、直方体形状、円
筒形状、楕円筒形状、球面状、非球面状でかつ形状の高
さａと配列ピッチｂとの比ｂ／ａが０．２〜５００であ
るものから選ばれる事を特徴とする請求項１または２に
記載の射出成形方法。3. The fine uneven shape provided on the mold surface is:
Structural units are prismatic, cubic, rectangular, cylindrical, elliptical cylindrical, spherical, aspherical, and the ratio b / a of the height a of the shape to the arrangement pitch b is 0.2 to 500. The injection molding method according to claim 1, wherein the injection molding method is selected from the following.
が、梨地状でＪＩＳＢ０６０１−１９９４法により測定
した表面粗さの最大高さ（Ｒｙ）が１〜１００μｍであ
る事を特徴とする請求項１または２に記載の射出成形方
法。4. The method according to claim 1, wherein the fine uneven surface provided on the surface of the mold has a satin-finished surface and a maximum surface roughness height (Ry) measured by JIS B0601-1994 method of 1 to 100 μm. The injection molding method according to claim 1.
ーボネート樹脂である事を特徴とする請求項１〜４に記
載の射出成形方法。5. The injection molding method according to claim 1, wherein the transparent resin is a methacrylic resin or a polycarbonate resin.
いて成形された事を特徴とする光学部品。6. An optical component formed by using the injection molding method according to claim 1. Description:
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP29835596A JP3875326B2 (en) | 1996-11-11 | 1996-11-11 | Injection molding method and optical component |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP29835596A JP3875326B2 (en) | 1996-11-11 | 1996-11-11 | Injection molding method and optical component |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH10138275A true JPH10138275A (en) | 1998-05-26 |
| JP3875326B2 JP3875326B2 (en) | 2007-01-31 |
Family
ID=17858621
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP29835596A Expired - Fee Related JP3875326B2 (en) | 1996-11-11 | 1996-11-11 | Injection molding method and optical component |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3875326B2 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2001183532A (en) * | 1999-10-14 | 2001-07-06 | Asahi Kasei Corp | Light guide plate and method of producing the same |
| US6625379B1 (en) * | 1999-10-14 | 2003-09-23 | Asahi Kasei Kogyo Kabushiki Kaisha | Light-conducting plate and method of producing the same |
| JP2012228810A (en) * | 2011-04-26 | 2012-11-22 | Asahi Kasei Corp | Method for molding resin |
-
1996
- 1996-11-11 JP JP29835596A patent/JP3875326B2/en not_active Expired - Fee Related
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2001183532A (en) * | 1999-10-14 | 2001-07-06 | Asahi Kasei Corp | Light guide plate and method of producing the same |
| US6625379B1 (en) * | 1999-10-14 | 2003-09-23 | Asahi Kasei Kogyo Kabushiki Kaisha | Light-conducting plate and method of producing the same |
| JP2012228810A (en) * | 2011-04-26 | 2012-11-22 | Asahi Kasei Corp | Method for molding resin |
Also Published As
| Publication number | Publication date |
|---|---|
| JP3875326B2 (en) | 2007-01-31 |
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