Replication Properties and Structure of PC in Micromolding with Heat Insulator Mold Using Zirconia Ceramic

Abstract

Abstract Micromolding with microscale surface features and thin-wall plates of polycarbonate polymer was performed with heat insulator molds using zirconia ceramic. Effects of process parameters on processability and surface replication of the molded optical parts such as anti-reflective plates were evaluated. Calculation results show the interfacial layer of molded parts with a heat insulator mold shows 20 K higher than a conventional mold. The state of replication and higher-order structure of molded parts were analyzed using a scanning electron microscope and a polarizing optical microscope. Using a heat insulator mold, the flow length is increased, and the state of surface replication of molded parts is better. Due to the better surface replication, plates using the insulator mold show higher light transmission due to the less light reflection at the surface of plates. The molecular orientation of molded parts decreased using this mold, as it did in molding conditions of higher mold temperatures and injection temperatures.