JP2017209155A - Method of fabricating mold having recessed pattern and method of manufacturing patterned sheet - Google Patents

Abstract

A method for manufacturing a mold having a concave pattern with high accuracy and excellent productivity and a method for manufacturing a pattern sheet are provided.
A method for producing a mold having a concave pattern includes preparing a mold having a first mold and a second mold for forming a cavity, and an electroforming mold having a needle-like pattern, and using the suction plate to form the electroforming mold. The step of fixing the electroformed mold to the first mold by suctioning the first mold and the second mold in the area other than the acicular pattern of the electroformed mold and the area other than the suction plate in order to form the cavity And a clamping process for clamping the electroformed mold, and an injection process for filling the cavity with resin.
[Selection] Figure 8

Description

  The present invention relates to a method for producing a mold having a concave pattern and a method for producing a pattern sheet.

  In recent years, Micro-Needle Array has been known as a new dosage form that can administer drugs such as insulin, vaccine (Vaccines) and hGH (human growth hormone) into the skin without pain. ing. The microneedle array is an array of biodegradable microneedles (also referred to as microneedles or microneedles) containing a drug. By affixing this microneedle array to the skin, each microneedle pierces the skin, the microneedle is absorbed in the skin, and the drug contained in each microneedle can be administered into the skin. The microneedle array is also called a transdermal absorption sheet.

  Various proposals have been made as a method for manufacturing a microneedle array having a fine pattern as described above. In Patent Document 1, a mold having a plurality of conical concave portions is prepared, the raw material of the needle is filled into the concave portions, the filled raw material is dried and solidified, and released from the mold. Manufacturing a needle array is disclosed.

JP 2013-074924 A

  Patent Document 1 discloses that a mold having a plurality of conical recesses may be formed by injection molding in which a mold is made of a resin melted in an original plate. However, no specific configuration is disclosed when injection molding is performed using an electroforming mold.

  The present invention has been made in view of such circumstances, and an object thereof is to provide a method for producing a mold having a concave pattern using an electroforming mold, and a method for producing a pattern sheet using the mold. .

  According to one aspect of the present invention, a method for producing a mold having a concave pattern includes preparing a mold having a first mold and a second mold forming a cavity, and an electroforming mold having a needle-like pattern, and an adsorption plate. In the step of fixing the electroforming mold to the first mold by sucking the electroforming mold by the step, and in order to form the cavity, in the area other than the needle-like pattern of the electroforming mold, and substantially in the area other than the suction plate, A mold clamping step of clamping the electroformed mold by the first die and the second die, and an injection step of filling the cavity with resin.

  Preferably, in the mold clamping step, the electroformed mold is clamped by the first mold and the second mold except for the end of the electroformed mold.

  Preferably, the resin is either a thermosetting resin or a silicone resin.

  Preferably, after the injection step, the resin in the cavity is cured by heating, then the first mold and the second mold are opened, and the mold release step is performed to release the cured resin from the needle-like pattern.

  Preferably, the electroforming mold is circular in plan view.

  Preferably, a flat surface is formed on the side where the first type electroformed mold is fixed, and a concave portion is formed on the side of the second mold cavity.

  According to another aspect of the present invention, a method for producing a pattern sheet includes a step of producing a mold having a concave pattern by the above-described method for producing a mold having a concave pattern, and a supply for supplying a polymer solution to the concave pattern of the mold. A step, a drying step of drying the polymer solution to form a polymer sheet, and a polymer sheet releasing step of releasing the polymer sheet from the mold.

  Preferably, the polymer solution includes a water-soluble material.

  According to the present invention, a mold can be produced using an electroforming mold with high accuracy and excellent productivity. A pattern sheet can be manufactured by this mold.

It is process drawing which shows the preparation methods of an electroforming metal mold | die. It is process drawing which shows the preparation methods of an electroforming metal mold | die. It is process drawing which shows the preparation methods of an electroforming metal mold | die. It is process drawing which shows the preparation methods of an electroforming metal mold | die. It is a perspective view of an electroforming mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the preparation methods of a mold. It is process drawing which shows the production method of another mold. It is process drawing which shows the production method of another mold. It is process drawing which shows the manufacturing method of a pattern sheet. It is process drawing which shows the manufacturing method of a pattern sheet. It is process drawing which shows the manufacturing method of a pattern sheet. It is process drawing which shows the manufacturing method of a pattern sheet. It is process drawing which shows the manufacturing method of a pattern sheet. It is process drawing which shows the manufacturing method of a pattern sheet.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. The invention is illustrated by the following preferred embodiments. Changes can be made by many techniques without departing from the scope of the present invention, and other embodiments than the present embodiment can be utilized. Accordingly, all modifications within the scope of the present invention are included in the claims.

  Here, in the drawing, portions indicated by the same symbols are similar elements having similar functions. In addition, in the present specification, when a numerical range is expressed using “˜”, upper and lower numerical values indicated by “˜” are also included in the numerical range.

<Mold production method>
Embodiments of the present invention will be described with reference to the drawings. The method for producing a mold having a concave pattern according to the present embodiment is prepared by preparing a mold having a first mold and a second mold that form a cavity and an electroforming mold having a needle-like pattern. The step of fixing the electroformed mold to the first mold by suction, and the formation of the cavity, the first mold and the second mold in the area other than the needle-like pattern of the electroformed mold and the area other than the suction plate And a mold clamping process for clamping the electroformed mold, and an injection process for filling the cavity with resin.

  An electroforming mold used for producing a mold is prepared. The electroforming mold is created based on, for example, process diagrams shown in FIGS. 1 to 4. As shown in FIG. 1, a mother die 10 for preparing an electroforming mold is prepared. On the first surface 12 of the mother die 10, a concave pattern 14 is formed that is an inverted shape of an electroforming mold having a convex pattern to be produced. The concave pattern 14 is a state in which a plurality of concave portions 16 are arranged in an array. The recess 16 is produced according to the shape of the electroforming mold to be produced. In the present embodiment, the recess 16 has a tapered shape from the first surface 12 toward the second surface 18. For example, examples of the tapered shape include a cone shape, a combination of a column shape and a cone shape, and a combination of a frustum shape and a cone shape. In the present embodiment, a plurality of concave patterns 14 are formed on the first surface 12 of the mother die 10.

  As shown in FIG. 2, the mother die 10 is fixed to the cathode 20 used for the electroforming process. The cathode 20 includes at least a shaft 22 and a cathode plate 24. The mother die 10 is fixed to the cathode plate 24 at a position where the second surface 18 of the mother die 10 and the cathode plate 24 face each other.

  When the mother die 10 is made of a resin material, a conductive process is performed on the mother die 10. A metal film (for example, nickel) is formed on the first surface 12 and the concave pattern 14 of the mother die 10 by vapor deposition or sputtering. In order to supply current from the cathode plate 24 to a metal film (not shown), a conductive ring 26 is provided on the outer periphery of the mother die 10. The shaft 22 and the cathode plate 24 are made of a conductive member. Here, electroforming treatment refers to a treatment method in which a metal is deposited on the surface of the mother die 10 by electroplating.

  As shown in FIG. 3, the mother die 10 attached to the cathode 20 is immersed in the electroforming liquid 32. As shown in FIG. 3, an electroforming apparatus 30 that performs an electroforming process on the mother die 10 includes an electroforming tank 34 that holds an electroforming liquid 32, and an electroforming liquid 32 </ b> A that overflows the electroforming tank 34. A drain tank 36 to be received and a titanium case 40 filled with Ni pellets 38 are provided. The cathode 20 with the mother die 10 attached is functioned as an electroforming apparatus 30 by immersing it in the electroforming liquid 32. As the electroforming liquid 32, for example, a liquid in which 400 to 800 g / L nickel sulfamate, 20 to 50 g / L boric acid, and necessary additives such as a surfactant (for example, sodium lauryl sulfate) are mixed. Can be used. The temperature of the electroforming liquid 32 is preferably 40 to 60 ° C.

  A drain pipe 42 is connected to the drain tank 36, and a supply pipe 44 is connected to the electroforming tank 34. The electroforming liquid 32 overflowed from the electroforming tank 34 to the drain tank 36 is recovered by the drain pipe 42, and the recovered electroforming liquid 32 is supplied from the supply pipe 44 to the electroforming tank 34. The mother die 10 held by the cathode 20 is aligned at a position where the first surface 12 on which the concave pattern 14 is formed faces the titanium case 40 serving as the anode.

  The cathode 20 is connected to the negative electrode, and the positive electrode is connected to the titanium case 40 serving as the anode. A DC voltage is applied between the cathode 20 and the titanium case 40 while rotating the mother die 10 held by the cathode plate 24 around the shaft 22 at a rotation speed of 10 to 150 rpm. The Ni pellets 38 are dissolved, and a metal film adheres to the concave pattern 14 of the mother die 10 attached to the cathode 20.

  When the electroforming mold 50 made of a metal film is formed on the mother die 10, the cathode 20 with the mother die 10 attached thereto is taken out from the electroforming tank 34 (not shown) as shown in FIG. Next, the electroforming mold 50 is peeled from the mother mold 10. The electroformed mold 50 having the first surface 52 and the second surface 58 and having the convex pattern 54 on the first surface 52 can be obtained. The convex pattern 54 is an inverted shape of the concave pattern 14 of the mother die 10.

  FIG. 5 is a perspective view of an electroforming mold. As shown in FIG. 5, the convex pattern 54 is a state in which a plurality of convex portions 56 are arranged in an array. In the present embodiment, the convex portion 56 has a tapered shape protruding from the first surface 52. For example, examples of the tapered shape include a cone shape, a combination of a column shape and a cone shape, and a combination of a frustum shape and a cone shape. In the present embodiment, a plurality of convex patterns 54 are formed on the first surface 52 of the electroforming mold 50. The height of the convex portion 56 is, for example, in the range of 0.2 mm to 2 mm, preferably 0.3 mm to 1.5 mm. The height of the convex portion 56 is the distance from the first surface 52 to the tip of the convex portion 56.

  In the electroforming process, in order to form a metal film having a uniform thickness on the first surface 12 of the mother die 10, the electroforming mold 50 is preferably circular in a plan view. The diameter of the electroforming mold 50 is preferably 200 to 300 mm. The circular shape is not limited to a perfect circle and may be a substantially circular shape.

  As will be described later, by performing injection molding using the electroforming mold 50, the electroforming mold 50 is transferred to produce a mold. As shown in FIG. 5, the area of the region where the plurality of convex patterns 54 is formed is smaller than the area of the electroforming mold 50. When a mold is produced on the entire surface of the electroforming mold 50, the produced mold may exceed an appropriate size and include an excess part. This surplus portion may cause resin loss and may require additional processing such as cutting.

  In injection molding, in order to easily fix and replace the electroforming mold 50, the electroforming mold 50 may be vacuum-sucked using an adsorption plate. During injection molding, it is required that the suction plate is not damaged. The inventors of the present invention diligently studied the injection molding using the electroforming mold 50 and arrived at the present invention.

  A method for producing a mold by injection molding will be described with reference to the process diagrams of FIGS.

  As shown in FIG. 6, a mold 70 including a first mold 72 and a second mold 74 is prepared. A cavity 76 is formed in the mold 70 by clamping the first mold 72 and the second mold 74. The cavity 76 means a space filled with resin.

  Since the electroforming mold 50 is fixed to the first mold 72, the side on which the electroforming mold 50 is fixed is constituted by a flat surface 78. The first mold 72 includes a suction plate 80 on a flat surface 78 as a device for fixing the electroforming mold 50. The first mold 72 includes a suction pipe 82 that communicates with the suction plate 80 in gas. The suction tube 82 is connected to a vacuum pump (not shown). By driving the vacuum pump, air can be sucked from the surface of the suction plate 80. By using the suction plate 80, the electroforming mold 50 can be easily fixed and replaced.

  The suction plate 80 is made of, for example, a porous member. As a porous member, a metal sintered compact, resin, a ceramic, etc. can be mentioned, for example. The suction plate 80 is required not to be damaged from the viewpoint of strength.

  A depression 84 is formed on the cavity 76 side of the second mold 74. In the present embodiment, a cavity 76 is formed by the flat surface 78 of the first mold 72 and a depression 84 (see FIG. 10) of the second mold 74 described later. By configuring the first mold 72 and the second mold 74 as described above, the mold can be easily released as described later.

  The second mold 74 is formed with a gate 86 communicating with the cavity 76. The gate 86 serves as a resin injection port into the cavity 76 of the mold 70. The gate 86 is in communication with an injection molding machine 88 that supplies resin to the mold 70. In the present embodiment, the resin is filled into the cavity 76 from a direction substantially parallel to the longitudinal direction of the cavity 76, that is, a so-called lateral direction.

  As shown in FIG. 7, the first mold 72 and the second mold 74 are opened, and the electroformed mold 50 having the convex pattern 54 is placed on the first mold 72. The second surface 58 of the electroforming mold 50 is vacuum-sucked to the suction plate 80 by sucking air with a vacuum pump through the suction pipe 82.

  As shown in FIG. 8, in the mold clamping process, in order to form the cavity 76, in the region other than the convex pattern 54 of the electroforming mold 50 and in the region other than the suction plate 80, The electroforming mold 50 is clamped by the second mold 74.

  The fact that the electroforming mold 50 is sandwiched between the first mold 72 and the second mold 74 in a region other than the suction plate 80 substantially means that the first mold 72 and the second mold 74 are used in the region other than the suction plate 80. This includes the case where the casting mold 50 is clamped and the case where the electroforming mold 50 is clamped by the first mold 72 and the second mold 74 in a region including a part of the suction plate 80, and the suction plate 80 is damaged by clamping. It means not receiving.

  Since the electroforming mold 50 is sandwiched between the first mold 72 and the second mold 74, the inner wall of the second mold 74 is located on the inner side of the outer edge 60 of the electroforming mold 50 as indicated by an arrow A in FIG. Is located. In plan view, the cavity 76 is smaller than the entire surface of the electroforming mold 50. As a result, the volume of the cavity 76 can be reduced, so that loss of resin can be avoided.

  In the present embodiment, the first mold 72 and the second mold 74 do not sandwich the electroformed mold 50 in the region of the suction plate 80. As indicated by the arrow B in FIG. 8, since the inner wall of the second mold 74 is located outside the suction plate 80, it is possible to avoid the suction plate 80 from being damaged. The inner side is a direction from the outer edge 60 of the electroforming mold 50 toward the center, and the outer side is a direction from the center of the electroforming mold 50 toward the outer edge 60. It is important to determine the position of the inner wall that defines the size of the cavity 76 (the inner wall that defines the width direction, not the height direction) so that the suction plate 80 is not damaged. As long as the suction plate 80 is not damaged, a part of the suction plate 80 can be clamped by the first mold 72 and the second mold 74.

  In this embodiment, the region excluding the end 62 of the electroforming mold 50 is clamped. As described above, the electroforming mold 50 is manufactured by supplying a current from the conductive ring 26 as shown in FIG. Therefore, the end 62 of the electroforming mold 50 that contacts the conductive ring 26 may have different physical properties (for example, thickness or surface roughness) as compared with other portions of the electroforming mold 50. .

  When the electroforming mold 50 has end portions 62 having different physical properties, when the electroforming mold 50 is used for injection molding, the electroforming mold 50 is stabilized by the first mold 72 and the second mold 74. In some cases, there is a concern about the accuracy of a molded product to be manufactured.

  Therefore, it is preferable not to pinch the end 62 as in the present embodiment.

  However, when there is no problem in the accuracy of the molded product to be manufactured, the end 62 of the electroforming mold 50 may be clamped by the first mold 72 and the second mold 74. The end portion 62 of the electroforming mold 50 is an area inside the outer edge 60 of the electroforming mold 50, and is an area having a physical property different from other areas excluding the convex pattern 54 of the electroforming mold 50. The physical properties are not limited to the thickness.

  According to the present embodiment, since the produced electroformed mold 50 can be fixed inside the mold 70 without processing the electroformed mold 50, it is possible to realize injection molding with high productivity. Become. Further, since the electroforming mold 50 is vacuum-sucked by the suction plate 80 and is clamped between the first mold 72 and the second mold, the electroforming mold 50 can be stably fixed, so that an accurate injection molding is performed. Can be realized.

  As shown in FIG. 9, the resin R is supplied from the injection molding machine 88 to the cavity 76 through the gate 86. The resin R is filled in the cavity 76 while passing between the convex patterns 54 of the electroforming mold 50. As the resin R, it is preferable to use an acrylic or epoxy thermosetting resin or a silicone resin, and it is particularly preferable to use a silicone resin. When the resin R is filled in the cavity 76 of the mold 70, the resin R is then heated and the resin R is cured.

  As shown in FIG. 10, in order to release the cured resin R from the electroforming mold 50, the first mold 72 and the second mold 74 that have been clamped are opened. In the mold opening, the first mold 72 and the second mold 74 are moved so as to be relatively separated from each other. As shown in FIG. 10, the second mold 74 has a recess 84 for forming a cavity 76. The cured resin R is a mold 100 in which a concave pattern 102 (see FIG. 14) before release is formed. Hereinafter, the mold 100 may be referred to.

  As shown in FIG. 11, the first mold 72 is separated from the second mold 74 and moved to a stage for releasing the mold 100 from the electroforming mold 50. In the present embodiment, since the second mold 74 having the depression 84 is separated from the mold 100, the mold 100 is exposed except for the surface in contact with the electroforming mold 50 fixed to the first mold 72. Become. Therefore, when the mold 100 is released from the electroforming mold 50, the mold 100 can be easily released using the exposed surface of the mold 100.

  As shown in FIG. 12, the periphery of the mold 100 is first separated from the electroforming mold 50. The peripheral portion of the mold 100 only needs to include at least two opposing sides when the mold 100 is viewed in plan, and may include all four sides. The peripheral edge means a region from the outer periphery of the mold 100 to the concave pattern 102.

  As shown in FIG. 13, the periphery of the mold 100 is gradually separated from the electroforming mold 50. When the mold 100 is made of a silicone resin, the mold 100 has an elastic force. Therefore, when the periphery of the mold 100 is gradually separated, the mold 100 is stretched (elastic deformation). When the peripheral portion of the mold 100 is further separated from the electroforming mold 50, the mold 100 that has been elastically deformed tends to return to its original shape, and thus the mold 100 contracts. The mold 100 is released from the electroforming mold 50 by utilizing the shrinking force of the mold 100. By utilizing the force that the mold 100 is trying to shrink as a releasing force, an excessive force is not applied between the mold 100 and the convex pattern 54 of the electroformed mold 50, thereby suppressing defective release. Is possible.

  As shown in FIG. 14, finally, the mold 100 and the convex pattern 54 of the electroforming mold 50 are completely released, and the mold 100 having the concave pattern 102 is manufactured. The concave pattern 102 is a state in which a plurality of concave portions 104 are arranged in an array.

  As a method of separating the peripheral edge of the mold 100 from the electroforming mold 50, it is an exposed surface opposite to the surface on which the concave pattern 102 is formed, and the peripheral edge of the mold 100 is sucked by a suction means, and the peripheral edge is sucked. A method of separating the suction means from the electroforming mold 50 can be given.

  When the mold 100 is repeatedly manufactured from the electroforming mold 50, the convex pattern 54 is gradually damaged. Therefore, when it is used about 1000 to 10,000 times, it is necessary to replace it with a new electroforming mold 50. In the present embodiment, the electroforming mold 50 can be replaced in a short time by stopping the driving of a vacuum pump (not shown) and reducing the suction force of the suction plate 80.

  In the present embodiment, an unprocessed electroforming mold 50 is used. As a result, an electroforming mold 50 that is circular in plan view and suitable for electroforming is preferably used in injection molding.

  FIGS. 15 and 16 are process diagrams showing a mold manufacturing method using a mold 70 of another form. As shown in FIG. 15, a depression 90 is formed in the first mold 72 of the mold 70 of the present embodiment. An electroforming mold 50 is installed on the bottom surface of the recess 90 and is vacuum-sucked to the first mold 72 via the suction plate 80.

  As shown in FIG. 16, the first mold 72 and the second mold 74 are clamped to form the cavity 76. The electroforming mold 50 installed in the recess 90 of the first mold 72 is sandwiched between the first mold 72 and the second mold 74. The inner wall of the second mold 74 is located inside the outer edge 60 of the electroforming mold 50 and outside the suction plate 80. In the present embodiment, the end portion 62 of the electroforming mold 50 is also sandwiched between the first mold 72 and the second mold 74.

  As shown in FIG. 16, the resin R is supplied from the injection molding machine 88 to the cavity 76 through the gate 86. The resin R is filled in the cavity 76 while passing between the convex patterns 54 of the electroforming mold 50.

<Pattern sheet manufacturing method>
Next, a method for producing a pattern sheet using the mold 100 produced by the above production method will be described. 17 to 22 are process diagrams for manufacturing the pattern sheet 110.

<Polymer solution supply process>
FIG. 17 shows a state where the mold 100 is prepared. The mold 100 is manufactured by the above-described mold manufacturing method. A mold 100 shown in FIG. 17 has a plurality of concave patterns 102. The concave pattern 102 is a state in which a plurality of concave portions 104 are arranged in an array.

  FIG. 18 is a diagram illustrating a process of supplying the polymer solution 112 to the concave pattern 102 of the mold 100.

  As a material of the polymer solution 112 that forms the pattern sheet 110, a water-soluble material is preferably used. As a resin polymer material of the polymer solution 112 used for manufacturing the pattern sheet 110, it is preferable to use a biocompatible resin. Such resins include glucose, maltose, pullulan, sodium chondroitin sulfate, sodium hyaluronate, saccharides such as hydroxyethyl starch, proteins such as gelatin, and biodegradable polymers such as polylactic acid and lactic acid / glycolic acid copolymers. It is preferable to use it. When the pattern sheet 110 is released from the mold 100, the pattern sheet 110 can be released using a base material (not shown), so that the pattern sheet 110 can be suitably used. Although the concentration varies depending on the material, it is preferable that the concentration of the resin polymer in the polymer solution 112 containing no drug is 10 to 50% by mass. Moreover, the solvent used for the polymer solution 112 may be volatile even if it is other than warm water, and alcohol such as ethanol can be used. And in the polymer solution 112, it is possible to dissolve together the medicine to be supplied into the body according to the application. The polymer concentration of the polymer solution 112 containing the drug (when the drug itself is a polymer, the concentration of the polymer excluding the drug) is preferably 0 to 30% by mass.

  As a method for preparing the polymer solution 112, when a water-soluble polymer (gelatin or the like) is used, a water-soluble powder may be dissolved in water, and a drug may be added after the dissolution. Alternatively, a water-soluble polymer powder may be put in and dissolved. If it is difficult to dissolve in water, it may be dissolved by heating. The temperature can be appropriately selected depending on the type of the polymer material, but it is preferable to heat at a temperature of about 20 to 40 ° C. as necessary. The viscosity of the polymer solution 112 is preferably 200 mPa · s or less, more preferably 50 mPa · s or less, in the case of a solution containing a drug. In a solution not containing a drug, it is preferably 2000 mPa · s or less, more preferably 500 mPa · s or less. By appropriately adjusting the viscosity of the polymer solution 112, the polymer solution 112 can be easily injected into the concave pattern 102 of the mold 100. For example, the viscosity of the polymer solution 112 can be measured with a capillary tube viscometer, a falling ball viscometer, a rotary viscometer, or a vibration viscometer.

  The drug contained in the polymer solution 112 is not limited as long as it has a function as a drug. In particular, it is preferable to select from peptides, proteins, nucleic acids, polysaccharides, vaccines, pharmaceutical compounds belonging to water-soluble low molecular weight compounds, or cosmetic ingredients.

  Examples of the method for injecting the polymer solution 112 into the mold 100 include application using a spin coater.

  It is preferable to form a through hole at the concave end of the concave pattern 102 of the mold 100. Air in the concave portion of the concave pattern 102 can escape from the through hole. Therefore, the polymer solution 112 can easily enter the recess of the mold 100. Further, this step is preferably performed in a reduced pressure state.

[Drying process]
FIG. 19 is a diagram illustrating a process of drying the polymer solution 112 to obtain a polymer sheet 114. For example, the polymer solution 112 supplied to the mold 100 can be dried by blowing air. The polymer sheet 114 means a state after the polymer solution 112 is subjected to a desired drying process. The moisture content of the polymer sheet 114 is set as appropriate. In addition, since it will become difficult to peel when the water content of a polymer becomes too low by drying, it is preferable to leave the water content in the state of maintaining elasticity.

  On the polymer sheet 114, a convex pattern 116, which will be described later, which is an inverted shape of the concave pattern 102 is formed.

[Polymer sheet release process]
20 and 21 are views showing a state in which the polymer sheet 114 is released from the mold 100 to form the pattern sheet 110. FIG. FIG. 22 is a diagram illustrating a process of cutting the pattern sheet 110 into individual pattern sheets 110A, 110B, 110C, and 110D.

  The pattern sheet 110 released from the mold 100 is set in a cutting device (not shown), and a position for cutting the pattern sheet 110 is determined. Basically, the cutting position is determined so that each of the regions 116A, 116B, 116C, and 116D having the convex pattern 116 is present. As shown in FIG. 22, the pattern sheet 110 is cut into a plurality of individual pattern sheets 110A, 110B, 110C, and 110D.

  Moreover, in FIGS. 17-22, although the method to manufacture the pattern sheet 110 using the mold 100 was demonstrated, it is not limited to this. For example, an assembly mold in which the area of the concave pattern 102 is increased can be manufactured by bonding a plurality of molds 100. A pattern sheet can also be manufactured using an assembly mold.

  By producing the pattern sheet using the assembly mold, a pattern sheet having a large area can be produced by one production, and productivity can be improved.

  In the present embodiment, the case where the polymer sheet 114 is formed by filling the polymer dissolution solution 112 into the concave pattern 102 of the mold 100 and drying is described, but the present invention is not limited to this.

  For example, the polymer solution 112 containing the drug is filled in the concave pattern 102 of the mold 100 and dried, and then the polymer solution 112 not containing the drug is filled in the concave pattern 102 of the mold 100 and dried to form two layers. A structured polymer sheet 114 can be formed.

  In addition, the mold 100 may be used only once for the first time, and may be preferably disposable. When the pattern sheet 110 is used as a medicine, it is preferable to make it disposable in consideration of the safety of the manufactured pattern sheet 110 to the living body. Moreover, since it becomes unnecessary to wash | clean the mold 100 by making it disposable, the cost by washing | cleaning can be reduced. In particular, when the pattern sheet 110 is used as a medicine, a high cleaning performance is required, so that the cleaning cost increases.

  The convex pattern 116 (regions 116A, 116B, 116C, 116D) of the pattern sheet 110 to be manufactured refers to a state in which a plurality of convex portions 118 are arranged in an array at a predetermined number and position. The convex portion 118 means a tapered shape on the tip side, and includes a cone shape and a multistage cone shape. The multi-stage cone shape means a cone shape having side surfaces with different angles from the bottom surface to the tip.

  The height of the convex portion 118 is in the range of 0.2 mm to 2 mm, and preferably 0.3 mm to 1.5 mm.

  The manufactured pattern sheet 110 having the convex pattern 116 is a replica of the electroformed mold 50 having the convex pattern 54. By making the shape and arrangement of the convex pattern 54 of the electroforming mold 50 a desired shape, the convex pattern 116 of the pattern sheet 110 to be manufactured can be made a desired shape.

10 Master 12 First surface 14 Concave pattern 16 Recess 18 Second surface 20 Cathode 22 Shaft 24 Cathode plate 26 Conductive ring 30 Electroforming device 32, 32A Electroforming liquid 34 Electroforming tank 36 Drain tank 38 Pellet 40 Titanium case 42 Drainage Piping 44 Supply piping 50 Electroformed mold 52 First surface 54 Convex pattern 56 Convex portion 58 Second surface 60 Outer edge 62 End portion 70 Mold 72 First die 74 Second die 76 Cavity 78 Flat surface 80 Suction plate 82 Suction tube 84 Indentation 86 Gate 88 Injection molding machine 90 Indentation 100 Mold 102 Concave pattern 104 Concave part 110, 110A, 110B, 110C, 110D Pattern sheet 112 Polymer solution 114 Polymer sheet 116 Convex pattern 116A, 116B, 116C, 116D Region 118 Convex part R resin

Claims (8)

A mold having a first mold and a second mold for forming a cavity and an electroformed mold having a needle-like pattern are prepared, and the electroformed mold is sucked by an adsorption plate so that the electroformed mold is moved to the first mold. Fixing to the mold,
In order to form the cavity, the electroforming mold is clamped by the first mold and the second mold in an area other than the needle-like pattern of the electroforming mold and substantially in an area other than the suction plate. Mold clamping process;
An injection step of filling the cavity with resin;
Method for producing a mold having a concave pattern having   2. The method for producing a mold having a concave pattern according to claim 1, wherein, in the mold clamping step, the electroformed mold is clamped by the first mold and the second mold except for an end portion of the electroformed mold.   The method for producing a mold having a concave pattern according to claim 1 or 2, wherein the resin is one of a thermosetting resin and a silicone resin.   After the injection process, the resin in the cavity is cured by heating, and then the first mold and the second mold are opened, and the cured resin is released from the acicular pattern. The manufacturing method of the mold which has a concave pattern as described in any one of Claim 1 to 3 which has a process.   The method for producing a mold having a concave pattern according to any one of claims 1 to 4, wherein the electroforming mold is circular in a plan view.   The flat surface is formed in the side which fixes the said electroforming metal mold | die of the said 1st type | mold, and a recessed part is formed in the said cavity side of the said 2nd type | mold. A method for producing a mold having a concave pattern. Producing a mold having a concave pattern by the method for producing a mold having a concave pattern according to any one of claims 1 to 6;
Supplying a polymer solution to the concave pattern of the mold;
A drying step of drying the polymer solution to form a polymer sheet;
A polymer sheet releasing step of releasing the polymer sheet from the mold;
The manufacturing method of the pattern sheet containing this.   The manufacturing method of the pattern sheet of Claim 7 in which the said polymer solution contains a water-soluble material.

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