Roll Mold Photocuring Process Eliminates Etching Variations
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Solution Overview
Problem
The existing roll mold manufacturing process is complex and prone to dimensional variations due to the need for multiple etching processes, increasing fabrication costs and complexity.
Innovation Solution
A method involving a substrate with a master pattern layer, a mold surface layer, and a solid buffer layer, where an adhesive resin layer is applied and cured using a light source, allowing the roll mold to adhere to a base roller without etching, simplifying the process and reducing variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple etching processes are used to pattern the base roller surface, then the roll mold can be formed with grooves, but the manufacturing process becomes complex and dimensional variations occur
Solution Approach 1:
The invention uses a master pattern that is copied onto the base roller surface through a single etching process. The master pattern contains the complete groove pattern information, which is transferred to the base roller in one step, eliminating the need for multiple sequential etching processes and reducing dimensional variations.
Solution Approach 2:
The master pattern is prepared in advance with the complete groove design. This preliminary preparation allows the base roller to be patterned in a single etching step by using the pre-prepared master pattern as a template, rather than requiring multiple iterative etching processes.
2Shape
If two etching processes are performed on the base roller, then the groove pattern is formed, but the diameter of the base roller decreases and deformation occurs
Solution Approach 1:
The groove pattern is copied from a master pattern to the base roller in a single etching operation. This one-step copying process removes material only where needed to form the grooves, rather than requiring multiple etching passes that progressively reduce the base roller diameter and cause deformation.
Solution Approach 2:
The master pattern is pre-formed with the exact groove geometry required. This preliminary action ensures that the single etching process transfers the precise pattern without requiring repeated material removal that would otherwise be necessary to achieve the same result through multiple etching steps.
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 simplifies the manufacturing process, reduces dimensional variations, and lowers costs by eliminating the need for etching, while ensuring accurate pattern formation and uniformity through the use of a photocurable mold resin and adhesive.
Implementation Method 1
curing the adhesive resin layer using a light source arranged in the base roller
Implementation Method 2
curing the mold surface layer using a light source arranged in the base roller
Implementation Method 3
The surface of the master pattern layer contacting the mold surface layer may be surface-treated with a hydrophobic material such as flurooctyl-trichloro-silane (FOTS) or (heptadecafluoro-1,1,2,3-tetrahydrodecyl)trichlorosilane (RDFS)
Data Source
AI summary
Discussed are a roll mold, a method for fabricating the same and a method for fabricating a thin film pattern using the same, which can prevent dimensional variation of the mold and simplify the overall process. The method for fabricating a thin film pattern includes providing a roll mold having a base roller provided with a light source, an adhesive resin layer formed on the base roller, a buffer layer formed on the adhesive resin layer, and a mold surface layer having a groove-protrusion shape formed on the buffer layer; forming a printing liquid on the roll mold or the substrate; and rolling the roll mold over the substrate to form a thin film pattern on the substrate. Also, the mold surface layer and the adhesive resin layer can be cured through light emitted from the light source arranged in the base roller.