Method for manufacturing microscopic structural body

Patent metadata

Field	Value
Publication number	US-9744698-B2
Application number	US-201113996777-A
Country	US
Kind code	B2
Filing date	Dec 1, 2011
Priority date	Dec 22, 2010
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

A method for manufacturing a molded product with fine structure includes steps of, in a temperature-controlled stamper mold provided with a fine structure including a concavo-convex pattern having a width of 10 nm to 1 μm, forming a thermoplastic molten polymer layer to be in contact with the fine structure 20 of the stamper mold having been kept at a predetermined temperature and holding the thermoplastic molten polymer layer for a predetermined time so as to transfer the fine structure of the stamper mold to the thermoplastic molten polymer layer under gravity.

First claim

The invention claimed is:

1. A method for manufacturing a molded product with fine structure, comprising steps of:
in a temperature-controlled stamper mold having a fine structure comprising a concavo-convex pattern having a width of 10 nm to 1 μm, coating a thermoplastic polymer onto the mold by discharging the thermoplastic polymer from a polymer discharge port of a T die while moving the T die over the mold and forming a thermoplastic molten polymer layer to be in contact with the fine structure of the stamper mold having been kept at a predetermined temperature; holding the thermoplastic molten polymer layer for a predetermined time so as to transcribe the fine structure of the stamper mold to the thermoplastic molten polymer layer under gravity so that the nano-sized fine pattern is transcribed to the thermoplastic molten polymer without pressurization by a pressurization apparatus;
cooling and solidifying the transcribed thermoplastic molten polymer layer; and
subsequently releasing the solidified thermoplastic molten polymer layer from the stamper mold.

2. A method for manufacturing a molded product with fine structure, comprising steps of:
in a temperature-controlled stamper mold having a fine structure comprising a concavo-convex pattern having a width of 10 nm to 1 μm, coating a thermoplastic polymer onto the mold by discharging the thermoplastic polymer from a polymer discharge port of a T die while moving the T die over the mold and forming a thermoplastic molten polymer layer to be in contact with the fine structure of the stamper mold having been kept at a predetermined temperature;
holding the thermoplastic molten polymer layer for a predetermined time so as to transcribe the fine structure to the thermoplastic molten polymer layer under gravity so that the nano-sized fine pattern is transcribed to the thermoplastic molten polymer without pressurization by a pressurization apparatus;
cooling and solidifying the transcribed thermoplastic molten polymer layer by temperature control of the stamper mold together with a mold brought into contact with a back surface of the thermoplastic molten polymer layer from the stamper mold; and
subsequently releasing the solidified thermoplastic molten polymer layer from the stamper mold.

3. The method for manufacturing a molded product with fine structure according to claim 2 ,
wherein pressurization force at the time when the mold is brought into contact with the back surface of the molten polymer layer from the stamper mold is 0.1 to 40 MPa.

4. A method for manufacturing a molded product with fine structure, comprising steps of:
in a temperature-controlled stamper mold provided with a fine structure comprising a fine pattern in which width of a concavo-convex pattern is nano-sized and a fine pattern in which width of a concavo-convex pattern is micro-sized, coating a thermoplastic polymer onto the mold by discharging the thermoplastic polymer from a polymer discharge port of a T die while moving the T die over the mold and forming a thermoplastic molten polymer layer to be in contact with the fine structure of the stamper mold having been kept at a predetermined temperature;
first, holding the thermoplastic molten polymer layer for a predetermined time so as to transcribe the nano-sized fine pattern to the thermoplastic molten polymer layer under gravity so that the nano-sized fine pattern is transcribed to the thermoplastic molten polymer without pressurization by a pressurization apparatus;
second, pressurizing the thermoplastic molten polymer layer so as to transcribe the micro-sized fine pattern to the thermoplastic molten polymer layer to completely transcribe the fine structure;
then, cooling and solidifying the completely transcribed thermoplastic molten polymer layer; and
subsequently releasing the solidified thermoplastic molten polymer layer from the stamper mold.

5. The method for manufacturing a molded product with fine structure according to claim 1 ,
wherein the formation of the molten polymer layer is performed by coating a thermoplastic molten polymer on an upper surface of the fine structure of the stamper mold under a coating pressure of 2 MPa or less so that a thickness of the polymer to be coated is determined by a distance between a polymer discharge port and the stamper mold and the shape and a thickness of the molten polymer layer become about the same as those of the transcribed final molded product with fine structure.

6. The method for manufacturing a molded product with fine structure according to claim 2 ,
wherein the formation of the molten polymer layer is performed by coating a thermoplastic molten polymer on an upper surface of the fine structure of the stamper mold under a coating pressure of 2 MPa or less so that a thickness of the polymer to be coated is determined by a distance between a polymer discharge port and the stamper mold and the shape and a thickness of the molten polymer layer become about the same as those of the transcribed final molded product with fine structure.

7. The method for manufacturing a molded product with fine structure according to claim 4 ,
wherein the formation of the molten polymer layer is performed by coating a thermoplastic molten polymer on an upper surface of the fine structure of the stamper mold under a coating pressure of 2 MPa or less so that a thickness of the polymer to be coated is determined by a distance between a polymer discharge port and the stamper mold and the shape and a thickness of the molten polymer layer become about the same as those of the transcribed final molded product with fine structure.

8. The method for method for manufacturing a molded product with fine structure according to claim 1 , wherein the discharge port of the T die has a flat tip.

9. The method for method for manufacturing a molded product with fine structure according to claim 2 , wherein the discharge port of the T die has a flat tip.

10. The method for method for manufacturing a molded product with fine structure according to claim 4 , wherein the discharge port of the T die has a flat tip.

11. The method according to claim 1 , wherein the predetermined time for holding the thermoplastic molten polymer layer without mechanically pressing the thermoplastic molten polymer layer is a time period at which a permeation length in a permeation length curve becomes a constant value.

12. The method according to claim 2 , wherein the predetermined time for holding the thermoplastic molten polymer layer without mechanically pressing the thermoplastic molten polymer layer is a time period at which a permeation length in a permeation length curve becomes a constant value.

13. The method according to claim 4 , wherein the predetermined time for holding the thermoplastic molten polymer layer without mechanically pressing the thermoplastic molten polymer layer is a time period at which a permeation length in a permeation length curve becomes a constant value.

Assignees

• Naito Akihiro
• Furuki Kenichi
• Ito Hiroshi
• Yakemoto Kazutoshi
• Japan Steel Works Ltd

Inventors

• Naito Akihiro
• Furuki Kenichi
• Ito Hiroshi
• Yakemoto Kazutoshi

Classifications

• B29C39/42

  Casting under special conditions, e.g. vacuum · CPC title

• B29C39/26

  Moulds or cores · CPC title

• B29C33/3857 Primary

  by making impressions of one or more parts of models, e.g. shaped articles and including possible subsequent assembly of the parts · CPC title

• B29C2043/3438

  moving during dispensing over the moulds, e.g. laying up · CPC title

• B81B2207/056

  of static structures · CPC title