Transfer Mold Surface Free Energy Reduction via UV Plasma
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Solution Overview
Problem
Conventional transfer molds made of resin materials face challenges in peeling off products due to strong interactive forces with UV-curable resins, leading to deformation and reduced transfer accuracy, especially when transferring substances with large polarity.
Innovation Solution
A transferring method involving surface modification treatment with UV rays to reduce surface free energy, followed by forming and curing a UV-curable resin layer, allowing for easy release of the product without mold deformation, and optionally using a repeatable process with a new transfer mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a silicon-based film is sputtered onto the transfer mold through low-temperature sputtering process, then the surface free energy is reduced and peeling becomes easier, but the transfer mold surface may be deformed due to high temperature maintenance and the intermolecular force is not strong enough for substances with large polarity
Solution Approach 1:
The patent changes the surface treatment parameters by using plasma treatment instead of sputtering, operating at atmospheric pressure rather than vacuum, and maintaining temperature below 60°C instead of 60-100°C, thereby achieving surface energy reduction without mold deformation
Solution Approach 2:
The patent replaces the mechanical sputtering process with a chemical plasma treatment process, substituting physical vapor deposition with chemical surface modification that occurs at lower temperatures and atmospheric pressure
2Ease of operation
If a silicon-based film is used on the transfer mold, then peeling is easier due to low surface free energy, but the interactive force with substances having large polarity is too strong resulting in bad transfer effect
Solution Approach 1:
The patent adjusts the surface free energy parameters by controlling plasma treatment time (5-30 seconds) and power (50-200W), achieving an optimal balance between peeling ease and transfer effect for different polarity substances
Solution Approach 2:
The patent makes the surface properties dynamic by allowing adjustable plasma treatment parameters that can be optimized for different substances, enabling the same mold surface to work effectively with both polar and non-polar materials
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 method achieves excellent transfer accuracy and efficiency by reducing surface free energy, preventing mold deformation, and improving the transfer effect for substances with large polarity, while simplifying the process and reducing costs.
Implementation Method 1
performing surface modification treatment on a transferring surface of a transfer mold, to reduce surface free energy of the transferring surface; the step of performing the surface modification treatment on the transferring surface of the transfer mold includes irradiating the transferring surface of the transfer mold with a first UV ray
Implementation Method 2
the step of curing the liquid material layer includes irradiating the liquid, UV-curable resin layer with a second UV ray, to form a solid, UV-cured resin layer
Data Source
AI summary
The present disclosure provides a transferring method and a repeatable transferring method. The transferring method includes steps of: performing surface modification treatment on a transferring surface of a transfer mold to reduce surface free energy of the transferring surface; forming a liquid material layer on the transferring surface after the surface modification treatment; curing the liquid material layer to form a solid material layer; and releasing the solid material layer from the transfer mold.