Method for preparing article having uneven microstructure on surface thereof

Patent metadata

Field	Value
Publication number	US-9138775-B2
Application number	US-201213990183-A
Country	US
Kind code	B2
Filing date	May 25, 2012
Priority date	May 26, 2011
Publication date	Sep 22, 2015
Grant date	Sep 22, 2015

Abstract

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.

First claim

The invention claimed is:

1. A method for preparing an article having an uneven microstructure on a surface thereof, comprising the following steps (I) and (II):
(I) 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 comprising a mold release agent, where the mold release agent consists of one or more (poly)oxyalkylene alkyl phosphoric ester compounds, where the pH of an aqueous solution resulting from extraction of 1 g of the mold release agent with 50 mL of water is 3.0 or more; and
(II) a step of, after the step (I), interposing an active energy ray curable resin composition comprising a polymerizable compound, a polymerization initiator, and an internal release agent between the mold and a substrate, and curing the active energy ray curable resin composition by irradiating the composition with active energy rays to form a cured resin layer having the uneven microstructure transferred thereto on the surface of the substrate, thereby obtaining an article having an uneven microstructure on a surface thereof,
wherein the (poly)oxyalkylene alkyl phosphoric ester compound is of a formula (1)
(HO) 3-n (O═)P[—O—(R 2 O) m —R 1 ] n   (1)

wherein R 1 is an alkyl group, R 2 is an alkylene group, m is an integer of 1 to 20, and n is an integer of 1 to 3.

2. The method for preparing the article according to claim 1 , wherein the release treatment solution is a 0.01 to 2.0% by weight aqueous solution of the mold release agent.

3. The method for preparing the article according to claim 1 , wherein the internal release agent of the active energy ray curable resin composition is a (poly)oxyalkylene alkyl phosphoric ester compound.

4. The method for preparing the article according to claim 1 , wherein the pH of an aqueous solution resulting from extraction of 1 g of the internal release agent with 50 mL of water is 3.0 or more.

5. The method for preparing the article according to claim 1 , wherein the mold release agent and the internal release agent are the same as each other.

6. The method for preparing the article according to claim 1 , wherein the difference in SP values between the mold release agent and the internal release agent is 2.0 or less.

Assignees

• Otani Go
• Nakai Yusuke
• Ozawa Satoru
• Mitsubishi Rayon Co

Inventors

• Otani Go
• Nakai Yusuke
• Ozawa Satoru

Classifications

• G02B1/118

  having sub-optical wavelength surface structures designed to provide an enhanced transmittance, e.g. moth-eye structures · CPC title

• B29C33/424

  Moulding surfaces provided with means for marking or patterning (for injection moulding B29C45/372) · CPC title

• B29C2035/0827

  using UV radiation · CPC title

• B29C59/046

  for layered or coated substantially flat surfaces · CPC title

• B29C39/148

  characterised by the shape of the surface · CPC title