Development of Belt-Type Microstructure Array Flexible Mold and Asymmetric Hot Roller Embossing Process Technology

Abstract

This study proposed the belt-type microstructure array flexible mold designed hot roller embossing process technology. An extrusion molding system was integrated with belt-type hot roller embossing process technology and, deriving the asymmetric principle as the basis of prediction, designed a belt-type microstructure array hot roller embossing process system. This study first focused on the design and manufacturing of a belt-type hot roller embossing process system (roll to belt-type). It then carried out system integration and testing, along with the film extrusion system, to fabrication microstructure array production. Hot embossing was used to replicate the array of the plastic micro lens as the microstructure mold. The original master mold was fabricated with micro electromechanical technology and the PC micro lens array as the microstructure (inner layer) film using the gas-assisted hot embossing technology. A microstructure composite belt and magnetic belt were produced on the hot roller embossing by an innovated coated casting technique. The forming accuracy of the belt-type microstructure array flexible mold hot roller embossing process and the prediction precision of numerically simulated forming were discussed. The proposed process technology is expected to effectively reduce the process cycle time with the advantages of being a fast and continuous process.

Forming of Dynamic Microstructure of Flexible Polymer

“…Considering the square column arrays, the appearance of the nanoimprint patterns of each square column exhibits a rhomb shape. Referring to Weng’s study [40] of the asymmetric theorem, this study set a single rectangular microstructure (Figure 4), array rectangular microstructure, array cylindrical microstructure, and the array microlens hemisphere structure for asymmetric imprint calculation prediction using MATLAB.…”

Nonuniform Heating Method for Hot Embossing of Polymers with Multiscale Microstructures

“…This process is cost-effective and facilitates mass production; therefore, it is widely used for fabricating optical films, biochips, small sensors, etc. Thus far, many effective polymer hot embossing methods have been proposed and developed, such as plate-to-plate hot embossing [ 1 , 2 , 3 ], gas-assisted hot embossing [ 4 , 5 , 6 , 7 ], ultrasonic hot embossing [ 8 , 9 , 10 , 11 ], roller hot embossing [ 12 , 13 , 14 , 15 ], soft mold-based hot embossing [ 16 , 17 , 18 , 19 ], and rapid hot embossing [ 20 , 21 , 22 ]. Most of these methods are isothermal hot-embossing processes with a uniform heating system.…”

A Study on the Dynamic Forming Mechanism Development of the Negative Poisson’s Ratio Elastomer Molds—Plate to Plate (P2P) Forming Process

“…Moreover, the micro/nano-structural substrates of different sizes and shapes [ 7 , 8 ] prepared by different processing methods (top-down, bottom-up) have high SERS enhancement factors and can be used for medical detection. At present, microstructural components, such as micro-nano gratings [ 9 , 10 , 11 , 12 , 13 , 14 ], polarizers, and lenses, can be completed by technologies such as nano-imprint, exposure, and development [ 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 ]. However, there is a problem of material selection if etching is used for microstructure fabrication.…”