Active Energy Ray-Curable Resin Composition Mold Release
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Solution Overview
Problem
Existing methods for creating fine concave-convex structures on surfaces using active energy ray-curable resin compositions face challenges with mold releasability, particularly with anodized alumina molds, leading to decreased productivity and precision due to high contact interfaces and the need for external release agents or high viscosity photocurable resins.
Innovation Solution
Incorporating a (poly)oxyethylene alkyl phosphate ester compound into the active energy ray-curable resin composition, which acts as an internal release agent, along with treating the mold surface with a release agent, to maintain long-term releasability and improve transfer precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an anodized alumina mold with fine pores is used, then the mold is easy to produce, but the contact interface between the mold and resin composition increases significantly, making it difficult to release the cured resin layer
Solution Approach 1:
A release agent is introduced as an intermediary substance between the anodized alumina mold surface and the resin composition. This release agent forms a intermediate layer that prevents direct adhesion between the mold pores and the cured resin, enabling easy production of the mold while maintaining easy releaseability during the molding process
Solution Approach 2:
The surface properties of the mold are modified by changing the chemical or physical parameters of the mold surface through release agent treatment. This alters the surface energy, roughness, or chemistry to reduce adhesion forces between the mold and resin, resolving the contradiction between easy mold production and easy release
2Ease of operation
If a release agent is applied to the mold surface, then releasability is improved, but the release agent is gradually stripped during repeated transfers, causing releasability to deteriorate over time
Solution Approach 1:
The mold surface is pre-treated with a release agent before each transfer operation. This preliminary action ensures that the release agent is freshly applied and not degraded from previous uses, maintaining high releasability throughout the entire molding process and preventing gradual deterioration over repeated transfers
Solution Approach 2:
The release agent is designed as a consumable material that is applied fresh for each transfer operation and then removed or degraded. This approach accepts that the release agent has a limited service life but ensures optimal performance for each individual transfer, avoiding the problem of cumulative degradation
3Ease of operation
If a solid photocurable transfer layer with phosphate ester-based compound is used, then internal release agent function is provided, but the fluidity is low, requiring high pressure and heat, which places load on the mold and apparatus
Solution Approach 1:
The physical state of the transfer layer is changed from solid to liquid or semi-liquid, reducing the viscosity and improving fluidity. This parameter change allows the transfer layer to flow and conform to the mold surface more easily under lower pressure and temperature conditions, while still providing the internal release agent function through the phosphate ester-based compound
Solution Approach 2:
The transfer layer is designed with hydraulic properties, utilizing fluid flow and pressure distribution to facilitate uniform transfer. The liquid or semi-liquid state allows the material to be pumped or flowed onto the mold surface, distributing the applied pressure more evenly and reducing peak stresses on the mold and apparatus
4Manufacturing precision
If high pressure and heat are applied to achieve transfer, then transfer precision may be improved, but the takt time increases and productivity decreases
Solution Approach 1:
The temperature and pressure parameters are optimized to achieve the minimum necessary for successful transfer. By changing these parameters to more favorable conditions (lower temperature and pressure), the transfer process becomes faster and more efficient, reducing takt time while maintaining adequate transfer precision through improved material flow and mold contact
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
The method ensures efficient and precise transfer of fine concave-convex structures with reduced peel strength and resin residue, maintaining high productivity even after repeated transfers.
Implementation Method 1
a (poly)oxyethylene alkyl phosphate ester compound, which acts as an internal release agent
Implementation Method 2
irradiation with active energy rays, thereby forming a cured resin layer
Data Source
AI summary
The present invention relates to a production method for a product having a cured resin layer with a fine concave-convex structure formed on the surface of a substrate, the method including filling the space between a mold having a fine concave-convex structure composed of anodized alumina on the surface and a substrate with an active energy ray-curable resin composition, and curing the composition by irradiation with active energy rays, thereby forming a cured resin layer into which the fine concave-convex structure has been transferred on the surface of the substrate, wherein (A) the method includes treating the surface of the mold with a release agent, at least at transfer initiation, and (B) the active energy ray-curable resin composition includes a polymerizable compound, a polymerization initiator and a (poly)oxyethylene alkyl phosphate ester compound.