Development of precision transfer technology of atmospheric hot embossing by ultrasonic vibration

We succeeded to transfer a precise micro-pattern combining with an ultrasonic vibration in an atmospheric hot embossing on the almost same condition as a vacuum hot embossing. This paper reports the effect of the ultrasonic vibration that was verified experimentally. In the conventional method, a metallic mold and a plastic sheet are heated more than the glass transition temperature of the plastic, and the softened plastic is flowed into the pattern only by applying a load. On the other hand, a longitudinal ultrasonic vibration is added in the molding process of an ultrasonic-vibration hot embossing. The synergy effect of the load and the ultrasonic vibration enables flowing of the plastic into a more precise pattern of the metallic mold. The longitudinal wave generated by an ultrasonic vibration system of the frequency 15 kHz and output 900 W. A pattern of the Ni mold used in the experiment was a pyramid hole in which a peak was cut and sidewalls were rounded. Entrance lengths of pyramids were from 100 to 530 μm and its all of the depth were 260 μm. A polycarbonate was chosen with a replication material. Compared with the condition that the ultrasonic vibration was not used, a contact force and a contact time could be reduced to about 1/3 and 1/12, respectively.