Soluble Mold Imprinting Using Taking Device and Solvent Dissolution
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Solution Overview
Problem
The existing imprinting methods face challenges in efficiently removing molds from articles without damaging the molds or deforming the fine structures, especially when using water-soluble polyvinyl alcohol (PVA) molds, which require precise curing and distribution, leading to increased mold damage and potential defects in the formed structures.
Innovation Solution
The method involves creating a soluble mold from a soluble material like polyvinyl alcohol, adhering a taking device to separate it from the master mold, applying temperature and pressure to transfer the mold pattern to a polymer layer, and then using a solvent to dissolve the mold, ensuring accurate alignment and minimizing structural defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a water-soluble PVA mold is used and cured to form a soluble mold, then the mold can be removed from the master mold, but the mold may remain on the article after mold release causing damage and defects
Solution Approach 1:
A taking device is introduced as an intermediary component between the soluble mold and the master mold. The taking device adheres to the soluble mold and facilitates its removal, preventing direct contact and adhesion between the mold and the article surface, thereby avoiding mold residue and defects
Solution Approach 2:
The taking device is adhered to the soluble mold before the molding process begins. This preliminary attachment ensures that when the soluble mold is removed from the master mold, it can be easily detached without leaving residue on the article, as the taking device acts as a buffer and release agent
2Strength
If the soluble material concentration and thickness are increased to improve mold strength, then the mold durability improves, but the curing time increases and operational complexity increases
Solution Approach 1:
The patent optimizes the concentration and thickness parameters of the soluble material to achieve the minimum necessary for mold strength while minimizing curing time. By carefully controlling these parameters, the mold achieves sufficient mechanical strength for handling and pattern transfer without requiring excessive curing duration
3Manufacturing precision
If the soluble material is evenly distributed on the article using a roller, then the mold distribution is uniform, but the fine structure deforms due to structure space expansion
Solution Approach 1:
The taking device is used to extract or remove the soluble mold from the master mold in a controlled manner. This prevents the mold material from being forced onto the article surface in a way that would cause deformation, while still achieving uniform distribution through the taking device's structured contact
4Measurement precision
If alignment marks are added to the soluble mold for precise alignment, then the alignment accuracy improves, but the alignment marks may interfere with the optical properties of the final optical element
Solution Approach 1:
The taking device serves as a temporary carrier that holds the soluble mold during alignment and molding operations. After the molding process, the taking device and soluble mold are removed, leaving only the imprint pattern on the article. This extraction process ensures that alignment marks and the soluble mold material do not remain on the final optical element, preventing optical interference
Solution Approach 2:
The soluble mold material and taking device are designed as temporary, disposable components that are discarded after serving their alignment and molding functions. Their soluble nature allows them to be easily removed without leaving permanent marks or interfering with the optical properties of the final element
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 enhances the ease of mold removal, improves the accuracy of the imprint pattern on the workpiece, reduces mold damage, and prevents alignment mark interference with the optical properties of the optical element, resulting in high-quality optical elements with precise and defect-free imprint patterns.
Implementation Method 1
providing a solvent to dissolve the soluble mold
Implementation Method 2
applying a high temperature and a pressure to the soluble mold to allow the polymer layer having an imprint pattern corresponding to the mold pattern and being solidified
Data Source
AI summary
The present invention provides an imprinting method, which includes the steps of: adding a soluble material to a master mold; solidifying the soluble material to form a soluble mold having a mold pattern; adhering a taking device to the soluble mold to separate the soluble mold from the master mold; placing the soluble mold on a polymer layer of a workpiece for imprint; applying a high temperature and a pressure to the soluble mold to allow the polymer layer having an imprint pattern corresponding to the mold pattern and being solidified, and to remove the taking device from the soluble mold; and providing a solvent to dissolve the soluble mold to obtain an imprint workpiece having the imprint pattern.