大面积微结构辊对板热压印装置研发及工艺优化

Development and Process Optimization of Large Area Micro-structure Roller-to-Plate Hot Stamping Device

目的研发一种模块化辊筒对平板类型的微结构热压加工装置,研究不同模具结构下的辊压工艺参数对光学聚合物微结构成形的影响,研究大尺寸的PMMA样品的翘曲规律。方法使用一种基于线接触的扫描连续辊压工艺,分别使用线槽模具、不锈钢网孔模具进行辊压实验,根据实验结果确定最佳工艺参数范围。结果在辊筒温度为150~180℃、平板温度为25℃、辊压压力为200~500 N和辊压速度为1 mm/s的工艺条件下,甲基丙烯酸甲酯平板(PMMA)微槽阵列的线槽宽复制度最高可达90%,微圆柱结构在40 mm×40 mm PMMA衬底的覆盖率高达95%。结论优化辊压工艺参数后,可以实现聚合物的大面积槽阵列和圆孔微透镜的稳定连续辊压成形。针对大面积光学聚合物翘曲的问题,进行了双面热辊压实验,发现二次成形后微透镜样品的最大高度偏差小于0.16 mm,翘曲现象得到了有效抑制。

The work aims to develop a new roller-to-plate hot stamping device for micro-structure machining and study the effect of rolling parameters on the micro-structure forming of optical polymer under different mold structures and the warping law of large-size PMMA samples.A scanning continuous rolling process based on line contact was used and the rolling experiments were carried out by linear groove mold and stainless steel mesh mold respectively.Then,the optimal process parameter range was determined according to the experimental results.When the roller temperature was 150℃ to 180℃,the plate temperature was 25℃,the forming force was 200 N to 500 N,and the rolling speed was 1 mm/s,the linear groove replication rate of large-size PMMA samples could reach 90%,and the coverage rate of micro-cylindrical structure on 40 mm×40 mm PMMA substrate was as high as 95%.After the optimization of rolling process parameters,the stable and continuous rolling forming of large area groove array and circular microlens of polymer can be realized.In order to solve the problem of large area optical polymer warping,double-sided hot rolling experiments have been carried out.It is found that the maximum height deviation of microlens samples after secondary forming is less than 0.16 mm,and the warping is effectively suppressed.