Mold release treatment method and method for producing anti-reflective film

Patent metadata

Field	Value
Publication number	US-9821494-B2
Application number	US-201314387623-A
Country	US
Kind code	B2
Filing date	Mar 25, 2013
Priority date	Mar 26, 2012
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

A mold release processing method according to an embodiment of the present invention includes the steps of: (a) providing a mold releasing agent, including a fluorine-based silane coupling agent and a solvent, and a mold of which the surface has a porous alumina layer; (b) applying the mold releasing agent onto the surface; and (c) heating, either before or after the step (b), the surface to a temperature not less than 40° C. and less than 100° C. in an ambient with a relative humidity of 50% or more.

First claim

The invention claimed is:

1. A mold release processing method comprising the steps of:
(a) providing a mold releasing agent, including a fluorine-based silane coupling agent and a solvent, and a mold of which the surface has a porous alumina layer;
(b) applying the mold releasing agent onto a surface of the porous alumina layer to which no mold releasing agent has been applied yet;
(c1) heating, after a final anodizing step of the mold and before the step (b), the surface of the porous alumina layer to a temperature not less than 40° C. and less than 100° C. in an ambient with a relative humidity of 50% to 90%; and
(c2) heating, after the step (b), the surface of the mold to a temperature not less than 50° C. and less than 100° C. in an ambient with a relative humidity of 50% to 90%.

2. The mold release processing method of claim 1 , further comprising the step of rinsing the surface of the mold, to which the mold releasing agent has been applied, with a fluorine-based solvent.

3. The mold release processing method of claim 1 , wherein the fluorine-based silane coupling agent included in the mold releasing agent has a concentration of not more than 0.002 mol/L.

4. The mold release processing method of claim 1 , wherein the fluorine-based silane coupling agent is perfluoropolyether-modified alkoxy silane.

5. The mold release processing method of claim 1 , wherein the step (b) is the only step for applying the mold releasing agent onto the surface of the porous alumina layer.

6. A method of making an antireflection film, the method comprising the steps of:
providing a mold which has been subjected to a mold release process, wherein the mold release process comprises the steps of:
(a) providing a mold releasing agent, including a fluorine-based silane coupling agent and a solvent, and a mold of which the surface has a porous alumina layer;
(b) applying the mold releasing agent onto a surface of the porous alumina layer to which no mold releasing agent has been applied yet;
(c1) heating, after a final anodizing step of the mold and before the step (b), the surface of the porous alumina layer to a temperature not less than 40*C and less than 100° C. in an ambient with a relative humidity of 50% to 90%; and
(c2) heating, after the step (b), the surface of the mold to a temperature not less than 50° C. and less than 100° C. in an ambient with a relative humidity of 50% to 90%; providing a workpiece;

irradiating a photocurable resin which is interposed between the mold and the workpiece with light, thereby curing the photocurable resin; and
peeling an antireflection film of the photocurable resin that has been cured off the mold.

Assignees

• Sharp Kk

Inventors

• Hayashi Hidekazu

Classifications

• B29L2011/00

  Optical elements, e.g. lenses, prisms · CPC title

• B29K2601/12

  Cellulose acetate · CPC title

• B29C59/02

  by mechanical means, e.g. pressing {(B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627)} · CPC title

• B29K2995/0064

  Non-uniform density · CPC title

• B29K2033/00

  Use of polymers of unsaturated acids or derivatives thereof as moulding material {(B29K2035/00 takes precedence)} · CPC title