Anti-Reflection Mold Plate Convex Structure

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Solution Overview

Problem

Existing anti-reflection articles face degradation issues due to mold plate abrasion, leading to increased manufacturing costs and reduced productivity, as the minute uneven structures on the mold plates tend to peel off over time, necessitating frequent replacements.

Innovation Solution

The anti-reflection article features a surface with densely arranged minute concave portions having multiple lowermost points, varying depths, and specific geometric arrangements, such as annular and earthenware mortar-shaped concave portions, which enhance the abrasion resistance of the mold plate, allowing for improved durability and reduced maintenance costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mold plate with minute uneven structure is used to manufacture anti-reflection articles, then the anti-reflection function is achieved, but the mold plate degrades over time due to abrasion and peeling

Engineering Contradiction:

Improvemold plate durabilityVSAvoidmold plate service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent inverts the conventional mold design by using a convex structure instead of a concave structure. The mold plate (5) is provided with a convex portion (61A, 62A, 63A) that protrudes toward the curable base (4), rather than having a concave portion that recesses into the base. This inversion prevents the minute uneven structure from adhering to and peeling off the curable base, thereby eliminating the degradation issue while maintaining the anti-reflection function.

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If the mold plate is replaced frequently due to degradation, then the anti-reflection article manufacturing continues, but the manufacturing cost increases

Engineering Contradiction:

Improvemanufacturing continuityVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

By inverting the mold structure to use a convex portion protruding toward the curable base, the patent eliminates the peeling and degradation problems that require frequent mold replacement. This single structural change enables the mold plate to maintain its anti-reflection function throughout the entire curable base without needing periodic replacement, thereby reducing manufacturing costs while ensuring continuous production.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If a conventional concave structure is used in the mold plate, then the anti-reflection function is achieved, but the minute uneven structure peels off after molding

Engineering Contradiction:

Improveanti-reflection functionVSAvoidmold structure stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies inversion by replacing the concave structure with a convex structure that protrudes toward the curable base. This convex portion (61A, 62A, 63A) maintains the necessary optical characteristics for anti-reflection functionality while fundamentally preventing the structure from adhering to and peeling off the curable base, thereby ensuring long-term structural stability.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent converts the potential harm of structure adhesion into a benefit by using the convex portion to actively prevent peeling. The protruding convex structure ensures that the minute uneven pattern remains stable on the curable base throughout the molding process and after curing, transforming the potential degradation issue into a durability advantage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration effectively suppresses mold plate degradation, maintains sufficient anti-reflection properties, and reduces manufacturing costs by extending the lifespan of the mold plate and improving the anti-reflection article's optical characteristics.

Implementation Method 1

an anti-reflection article that exhibits an anti-reflection function by the dense arrangement of a plurality of minute convex portions with a gap of the shortest wavelength of a wavelength band or less of an electromagnetic wave for anti-reflection

Methodology Applied

Scientific EffectAnti-reflection: Anti-Reflective Coating

Implementation Method 2

at least some of the minute concave portions are a minute concave portion with multiple lowermost points in the minute concave portion

Methodology Applied

Scientific EffectLight trapping: Absorption (EM radiation)

Data Source

PatentUS9158040B2Anti-reflection article

Publication Date: 2015.10.13 DAI NIPPON PRINTING CO LTD

AI summary

To provide an anti-reflection article which can be manufactured by using an anti-reflection article manufacturing mold plate having improved abrasion resistance compared to the related art and has a sufficient anti-reflection property. An anti-reflection article is formed as an anti-reflection article in which minute concave portions are densely arranged and the gap between the adjacent minute concave portions is the shortest wavelength of a wavelength band or less of an electromagnetic wave for anti-reflection. In the anti-reflection article, at least some of the minute concave portions are a minute concave portion with multiple lowermost points in the minute concave portion.