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Study on non-isothermal hot-embossing of polymer micro-prism array with efficiency and accuracy.

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Title: Study on non-isothermal hot-embossing of polymer micro-prism array with efficiency and accuracy.
Authors: Hu, Manfeng1, Xie, Jin1 jinxie@scut.edu.cn, Li, Wenzhe1, Lu, Kuo1
Source: Journal of Materials Processing Technology. Apr2019, Vol. 266, p675-686. 12p.
Subjects: Microforms, Nanostructured materials, Surface roughness, Embossing (Metalwork), Metal finishing
Abstract: Graphical abstract Abstract The isothermal hot-embossing leads to inefficiency because of heating and cooling whole polymer workpiece for precision micro-forming. Hence, a non-isothermal hot-embossing is proposed by compressing and melting a micron-scale surface layer into heated core microgrooves without changing the solid-state workpiece. The objective is to understand how the upper layer micro-prism array is formed on large-size polymer surface with regard to core microgroove parameters and hot-embossing variables. First, the micro-prism shape and sizes were in-process modeled through a hybrid of mechanical compression and hot-melt flowing inside core microgrooves; then the micro-grinding with the trued wheel micro-tip was employed to fabricate various microgrooves on macro-size die cores; finally, the micro-forming accuracy and efficiency were experimentally investigated in hot-embossing. It is shown that the integrated micro-prism array with nanometer-scale surface roughness is rapidly generated inside accurate and smooth core microgrooves with 1–3 seconds. The micro-forming accuracy is dominated by the hot-embossing variables under the limitations of core microgroove parameters. Moreover, the hot-embossed surface roughness reaches 10–30 nm through the hot-melt layer flowing even if the core surface roughness is larger. It is confirmed that the rapid micro-forming sizes and surface roughness may be predicted by the micro-nano core topographies and the hot-embossing variables. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:Graphical abstract Abstract The isothermal hot-embossing leads to inefficiency because of heating and cooling whole polymer workpiece for precision micro-forming. Hence, a non-isothermal hot-embossing is proposed by compressing and melting a micron-scale surface layer into heated core microgrooves without changing the solid-state workpiece. The objective is to understand how the upper layer micro-prism array is formed on large-size polymer surface with regard to core microgroove parameters and hot-embossing variables. First, the micro-prism shape and sizes were in-process modeled through a hybrid of mechanical compression and hot-melt flowing inside core microgrooves; then the micro-grinding with the trued wheel micro-tip was employed to fabricate various microgrooves on macro-size die cores; finally, the micro-forming accuracy and efficiency were experimentally investigated in hot-embossing. It is shown that the integrated micro-prism array with nanometer-scale surface roughness is rapidly generated inside accurate and smooth core microgrooves with 1–3 seconds. The micro-forming accuracy is dominated by the hot-embossing variables under the limitations of core microgroove parameters. Moreover, the hot-embossed surface roughness reaches 10–30 nm through the hot-melt layer flowing even if the core surface roughness is larger. It is confirmed that the rapid micro-forming sizes and surface roughness may be predicted by the micro-nano core topographies and the hot-embossing variables. [ABSTRACT FROM AUTHOR]
ISSN:09240136
DOI:10.1016/j.jmatprotec.2018.11.041