Phosphate Ester Release Agent for Mold Erosion in UV Cured Films
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Solution Overview
Problem
Existing methods for producing transparent films with fine uneven structures face challenges in maintaining mold releasability and preventing mold surface erosion, leading to decreased anti-reflective performance and productivity.
Innovation Solution
The use of a phosphate ester compound with a specific pH value of 6.5 to 7.5 and phosphoric acid concentration of 50 ppm or less as an internal release agent in the active-energy-ray-curable composition, which prevents mold surface erosion and maintains long-term releasability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an external release agent is used on the mold surface, then releasability between the mold and cured resin layer is improved, but the external release agent peels off after repeated transfers and releasability gradually decreases
Solution Approach 1:
The invention extracts the release agent function from the external application method and incorporates it into the curable composition itself as an internal release agent. The phosphate ester compound is embedded within the curable composition, allowing it to exert its release effect during the curing process without being applied externally to the mold surface, thereby eliminating the peeling problem of external release agents.
Solution Approach 2:
The phosphate ester compound acts as an intermediary substance between the mold surface and the cured resin layer. It provides a release function by forming a barrier layer during curing, facilitating easy separation without direct contact between the mold surface and the cured resin, thus preventing adhesion while maintaining mold surface integrity.
2Ease of operation
If an internal release agent containing phosphate ester compound is used, then releasability is improved, but phosphoric acid erodes the mold surface and fine uneven structure varies
Solution Approach 1:
The invention changes the chemical parameters of the phosphate ester compound by strictly controlling the phosphoric acid concentration to 50 ppm or less and adjusting the pH to 6.5-7.5. These parameter modifications reduce the corrosiveness of the phosphate ester compound while preserving its release function, thereby preventing mold surface erosion and maintaining the consistency of the fine uneven structure.
Solution Approach 2:
The invention converts the potentially harmful phosphoric acid into a beneficial component by controlling its concentration at extremely low levels (50 ppm or less). At this low concentration, the phosphoric acid no longer causes erosion but retains the release properties of the phosphate ester compound, transforming a harmful factor into a safe and effective release agent.
3Manufacturing precision
If the contact interface between mold and curable composition is increased due to nanometer-scale fine pores with large aspect ratio, then fine uneven structure transfer is improved, but mold release becomes difficult
Solution Approach 1:
The invention applies preliminary action by incorporating the phosphate ester compound into the curable composition before curing. This internal release agent creates a release barrier during the curing process itself, preventing strong adhesion between the curable composition and the mold surface with high aspect ratio fine pores, thereby ensuring easy release after curing.
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 approach allows for continuous production of transparent films with fine uneven structures while maintaining excellent anti-reflective properties and preventing mold surface erosion, ensuring consistent product quality.
Implementation Method 1
the surface of the side of the mold on which the fine uneven structure has been formed is treated with a release agent (external release agent)
Implementation Method 2
erosion of a surface of a mold is due to that phosphoric acid remaining in the phosphate ester compound commonly used as an internal release agent dissolves the surface of the mold
Implementation Method 3
a process of irradiating the active-energy-ray-curable composition by an active energy ray such as an ultraviolet ray or the like to cure the same, thus forming a cured resin layer having a fine uneven structure
Implementation Method 4
a process of sandwiching an active-energy-ray-curable composition between a mold having an inverted structure of a fine uneven structure on a surface thereof and a base film serving as a body of the transparent film
Implementation Method 5
a process of separating the transparent film and the mold
Data Source
AI summary
Described are: an active-energy-ray-curable composition (38) containing a phosphate ester compound of which an aqueous solution prepared by extracting with 50 mL of water per 1 g of the phosphate ester compound has a pH value of 6.5 to 7.5 at 25° C., wherein the value of (the concentration of phosphoric acid in the aqueous solution, expressed in mass ppm)×(the content of the phosphate ester compound in the active-energy-ray-curable composition, expressed in mass %) is 50 or less; and a process for producing a transparent film (40) which includes the active-energy-ray-curable composition (38) and in which a cured resin layer (44) having a fine uneven structure is formed on the surface of a base film (42).