Phosphoric Acid Mold Release for Microstructure Transfer
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Solution Overview
Problem
The existing methods for preparing articles with uneven microstructures using anodized alumina oxide molds face challenges in maintaining mold releasability and surface characteristics during repeated transfers, leading to reduced productivity and altered optical properties due to issues with mold release agents, such as fluorine-containing silane compounds, which are costly and prone to aggregation.
Innovation Solution
A method involving the use of a (poly)oxyalkylene alkyl phosphoric acid compound as a mold release agent, applied as a 0.01 to 2.0% aqueous solution with a pH of 3.0 or more, to coat the mold surface, and incorporating the same compound as an internal release agent in the active energy ray curable resin composition, ensures stable releasability and maintains the shape and surface characteristics of the transferred microstructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluorine-containing silane compound is used as a mold release agent, then the mold can be released from the cured resin layer, but the cost increases and the release agent aggregates on the mold surface
Solution Approach 1:
The patent changes the chemical parameters of the release agent by using phosphoric acid compounds with specific pH values (3.0 or more) and specific molecular structures (polyoxyalkylene alkyl phosphoric acid compounds). This parameter change eliminates aggregation while maintaining effective mold release, resolving the contradiction between releasability and aggregate formation.
Solution Approach 2:
The patent employs a cost-effective phosphoric acid compound that can be applied as a water-soluble solution, eliminating the need for expensive fluorine-containing silane compounds. The release agent is applied, performs its function, and can be easily removed with water, making it a disposable-like system that is economical and non-aggregating.
2Reliability
If a mold release agent is applied to the mold surface, then the mold can be released from the cured resin layer, but the release agent detaches during repeated transfers and migrates to the article surface
Solution Approach 1:
The patent modifies the chemical parameters of the release agent by selecting phosphoric acid compounds with pH ≥ 3.0 and specific molecular structures that provide both effective release and surface stability. These parameter changes prevent the release agent from detaching and migrating to the article surface during repeated transfers, maintaining surface characteristic stability.
Solution Approach 2:
The phosphoric acid compound acts as an intermediary that remains on the mold surface during transfers, mediating between the mold and the cured resin layer. Its specific chemical properties allow it to maintain its position on the mold surface rather than migrating to the article, thus stabilizing surface characteristics.
3Reliability
If the aspect ratio of pores in the anodized alumina oxide mold is increased to obtain sufficient antireflective effect, then the optical performance improves, but the contact interface area between mold and resin increases
Solution Approach 1:
The patent optimizes the pore aspect ratio parameter in the anodized alumina oxide mold to achieve sufficient antireflective effect while controlling the contact interface area. By carefully selecting the aspect ratio range, the patent resolves the contradiction between optical performance and contact area.
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 stable and high-productivity preparation of articles with maintained microstructure and optical properties even after multiple transfers, avoiding the drawbacks of traditional mold release agents and ensuring efficient transfer and surface integrity.
Implementation Method 1
a step of coating a surface of a mold having an uneven microstructure formed from an anodized alumina oxide on a surface thereof with a release treatment solution including a mold release agent
Implementation Method 2
an active energy ray curable resin composition is interposed between a mold having an uneven microstructure on a surface thereof and a substrate and cured by the irradiation with active energy rays
Implementation Method 3
as the mold, a mold having an anodized alumina oxide with plural pores on a surface of an aluminum-based substrate attracts interest
Data Source
AI summary
A method for preparing an article having an uneven microstructure on a surface thereof, including coating a surface of a mold having an uneven microstructure formed from an anodized alumina oxide on a surface with a release treatment solution including a mold release agent that includes one or more kinds of phosphoric ester compound and the pH of the aqueous solution when extracted with 50 mL of water with respect to 1 g of the mold release agent is 3.0 or more; and interposing an active energy ray curable resin composition including a polymerizable compound, a polymerization initiator, and an internal release agent between the mold and the substrate, and curing the active energy ray curable resin composition by the irradiation with active energy rays to form a cured resin layer having the uneven microstructure transferred on a surface of the substrate.