MOLD FOR PROCESSING OPTICAL FILM AND MANUFACTURING METHOD THEREOF

• US 20120070524A1
• Filed: 11/22/2010
• Published: 03/22/2012
• Est. Priority Date: 09/21/2010
• Status: Abandoned Application

• Current Assignee: Hon Hai Precision Industry Co., Ltd.
• Original Assignee: Hon Hai Precision Industry Co., Ltd.
• Inventors: HSU, CHIA-LING
• Application Number:
  US12/952,159
• Publication Number:
  US 20120070524A1
• Time in Patent Office: Days
• US Class Current: 425/115
• CPC Class Codes: B29C 33/424 Moulding surfaces provided with means for marking or patterning for injection moulding B29C45/372
• CPC Class Codes: B29C 33/56 Coatings , e.g. enameled or galvanised; Releasing, lubricating or separating agents in-mould coating B29C37/0028; using or applying separating agents B29C37/0067

Abstract

A mold for processing an optical film includes a substrate defining a microstructure on an outer surface thereof for printing a pattern on the optical film, an aluminum oxide film, and a hydrophobic fluorinated self-assembled monolayer film. The aluminum oxide film is formed on an outer surface of the substrate by atomic layer deposition. The hydrophobic fluorinated self-assembled monolayer film is formed on an outer surface of the aluminum oxide film. The mold provides easy release of the hydrophobic fluorinated self-assembled monolayer film and protection for the mold from abrasion.

Claims

1. A method for manufacturing a mold for processing an optical film, comprising:

providing a substrate defining a microstructure on an outer surface thereof for printing a pattern on the optical film;

performing an atomic layer deposition process to form an aluminum oxide film on the outer surface of the substrate; and

dehydrating the aluminum oxide film with a fluorinated fatty acid to form a fluorinated self-assembled monolayer film on an outer surface of the aluminum oxide film.

2. The method of claim 1, wherein the step of performing the atomic layer deposition process comprising:

placing the substrate in a chamber at a pressure of 0.1 Torr and a temperature between 100°

C. and 400°

C.; and

introducing a precursor and an oxidant into the chamber.

3. The method of claim 2, wherein the precursor is trimethyl aluminum (TMA, (CH₃)₃Al) and the oxidant is oxygen.

4. The method of claim 2, wherein the precursor comprises AlCl₃, (C₂H₅)₃Al or (C₃H₇)₃Al.

5. The method of claim 2, wherein the oxidant comprises O₃ or H₂O.

6. The method of claim 1, wherein the step of dehydrating the aluminum oxide film comprising:

placing the substrate having the aluminum oxide film in a chamber filled with an inert gas;

introducing the fluorinated fatty acid into the chamber; and

heating the chamber to vaporize the perfluorinated fatty acid.

7. The method of claim 6, wherein the temperature of dehydrating the aluminum oxide film is higher than a vaporizing temperature of the perfluorinated fatty acid

8. The method of claim 7, wherein the temperature of dehydrating the aluminum oxide film is 200°

C.

9. The method of claim 6, wherein a concentration of the perfluorinated fatty acid is 0.2% of volume of the chamber.

10. The method of claim 6, wherein the fluorinated fatty acid is a perfluorinated fatty acid with long linear carbon chain (CF₃(CF₂)nCOOH), wherein n is 3, 6, 8, 10, or 16.

11. The method of claim 6, wherein the fluorinated fatty acid is a partial perfluorinated fatty acid with long linear carbon chain (CF₃(CF₂)_n(CH₂)_mCOOH), wherein each of n+m is 3, 6, 8, 10, or 16, and n and m are both integers.

12. The method of claim 6, further comprising washing an outer surface of the fluorinated self-assembled monolayer film with chloroform, acetone, alcohol, and deionized water sequentially.

13. The method of claim 1, wherein the aluminum oxide film has a thickness between 50 nm and 150 nm

14. A mold for processing an optical film comprising:

a substrate defining a microstructure on an outer surface thereof for printing a pattern on the optical film, an aluminum oxide film formed on an outer surface of the substrate, and a fluorinated self-assembled monolayer film formed on an outer surface of the aluminum oxide film, wherein the fluorinated self-assembled monolayer film is formed by dehydration with the aluminum oxide film and the fluorinated fatty acid.

15. The mold for processing an optical film of claim 14, wherein the fluorinated self-assembled monolayer film is a perfluorinated self-assembled monolayer film or a partial fluorinated self-assembled monolayer film.

16. The mold for processing an optical film of claim 14, wherein substrate is in a form of a roller.

17. The mold for processing an optical film of claim 16, wherein the microstructure comprises a plurality of V-shaped recessions extending along an axis of the substrate.