Mold, Method for the Production and Use Thereof, Plastic Film and Plastic Component

Abstract

The invention relates to a method for creating a surface structure on a mold, wherein first structural elements are created using a laser structuring process in a first step, and second structural elements, which are smaller than the first structural elements, are created using an anodic oxidation process in another step following the laser structuring process. The invention further relates to a mold of said type and finally to a plastic film or a plastic component having a surface structure as well as to a method for the production thereof.

Claims

1-24. (canceled)

25. A method for producing a surface structure on a molding tool comprising: producing first structural elements by laser structuring; and producing second structural elements by anodic oxidation, the second structural elements being smaller than the first structural elements.

26. The method of claim 25, wherein said step of producing first structural elements comprises producing first structural elements having a lateral extension of about 0.5 μm to about 500 μm.

27. The method of claim 25, wherein said step of producing first structural elements comprises producing first structural elements having a height of about 0.5 μm to about 200 μm.

28. The method of claim 25, wherein said steps of producing first structural elements and producing second structural elements are performed on a molding tool that contains, or consists of, a metal or a metal alloy.

29. The method of claim 25, wherein said steps of producing first structural elements and producing second structural elements are performed on a molding tool comprising aluminum or titanium.

30. The method of claim 25, wherein said step of producing second structural elements comprises carrying out the anodic oxidation in a multi-stage method to produce the second structural elements, said multi-stage method including the following steps: a first anodic oxidation at least a partial removal of an oxide layer by wet chemical etching at least one second anodic oxidation optionally opening of the pores formed in the preceding steps.

31. The method of claim 25, comprising the step of: electropolishing the surface of the molding tool after carrying out the laser structuring and before producing the second structural elements.

32. The method of claim 25, comprising the step of: tempering the molding tool at a temperature of about 800° C. to about 1300° C.

33. The method of claim 32, wherein said step of tempering the molding tool comprises tempering the molding tool in a protective gas atmosphere.

34. The method of claim 25, wherein the molding tool comprises aluminum and said step of producing said second structural elements by anodic oxidation results in formation of γ-aluminum oxide on the surface of the molding tool and said method comprises: at least partially converting the γ-aluminum oxide into α-aluminum oxide on the surface of the molding tool.

35. The method of claim 25, comprising the step of: depositing a non-stick coating comprising a plasma polymer by means of PE-CVD which has a thickness of about 5 nm to about 30 nm.

36. A molding tool with a surface structure including: first structural elements having a lateral extension of about 0.5 μm to about 500 μm; and second structural elements having a lateral extension smaller by a factor of at least 10 than the lateral extension of the first structural elements, wherein at least part of the surface of the molding tool is covered with aluminum oxide.

37. The molding tool of claim 36, wherein the second structural elements are applied onto an entire surface of the first structural elements.

38. The molding tool of claim 36, wherein the molding tool comprises a metal or an alloy selected from a group consisting of aluminum or titanium.

39. The molding tool of claim 36, wherein at least part of the surface of the molding tool contains a non-stick coating comprising a plasma polymer having a thickness of about 5 nm to about 30 nm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The invention shall be specified below by means of drawings without confining the general inventive concept, wherein

[0037] FIG. 1 shows part of a molding tool without surface structure.

[0038] FIG. 2 shows part of a molding tool having first structural elements.

[0039] FIG. 3 shows part of a molding tool after the electropolishing operation.

[0040] FIG. 4 shows part of a molding tool after the production of second structural elements.

[0041] FIG. 5 shows part of a molding tool after the stabilization of the second structural elements.

[0042] FIG. 6 shows part of a molding tool after the application of a non-stick coating.

[0043] FIG. 7 shows by way of example the application of a molding tool in a first method step of an injection molding method.

[0044] FIG. 8 shows by way of example the use of the molding tool in a second method step of an injection molding method.

[0045] FIG. 9 shows by way of example a plastic component or a plastic film according to a first embodiment of the invention.

[0046] FIG. 10 shows by way of example a plastic film or a plastic component according to a second embodiment of the invention.

[0047] FIG. 11 shows a device for hot stamping according to the present invention.

[0048] FIG. 12 shows the first method step of a hot stamping method according to the invention in a first embodiment.

[0049] FIG. 13 shows the second method step of a hot stamping method according to the invention in a first embodiment.

[0050] FIG. 14 shows the third method step of a hot stamping method according to the invention in a first embodiment.

[0051] FIG. 15 shows the first method step of a hot stamping method according to the invention in a second embodiment.

[0052] FIG. 16 shows a second method step of the hot stamping method according to the invention in a second embodiment.

[0053] FIG. 17 shows the third method step of a hot stamping method according to the invention in a second embodiment.

DETAILED DESCRIPTION

[0054] The method according to the invention, which is used to produce a molding tool, is explained by means of FIGS. 1 to 6. FIGS. 1a, 2a, 3a, 4a, 5a and 6a each show an axonometric view. FIGS. 1b, 2b, 3b, 4b, 5b and 6b show a cross-section through the molding tool.

[0055] The basic substrate of the molding tool 2 is provided in the first method step. The basic substrate can contain a metal or an alloy. In some embodiments of the invention, the basic substrate can contain aluminum or titanium. These materials can easily be processed and also form a stable oxide layer on the surface thereof, which due to their hardness guarantee low abrasive wear of the molding tool and are chemically inert to a large extent.

[0056] The described embodiment uses an approximately rectangular initial substrate having a first side 21 and an opposite second side 22. In other embodiments of the invention, the substrate can have another basic form. In particular, an approximately cylindrical molding tool can be used for continuous hot stamp processes.

[0057] FIG. 2 shows the molding tool after carrying out a first method step, in which first structural elements 11A and 11B are produced. The first structural elements can be made e.g. by laser structuring. Here, the laser radiation effects the removal of material such that e.g. a groove 11A or a plurality of bores 11B can be produced on the first side 21 of the molding tool 2. In other embodiments of the invention, the first structural elements can have a different form. However, the invention is specified in the below figures by way of example by means of a groove 11A as a first structural element 11. The form of the first structural elements 11 can be selected in accordance with the desired intended use of the structured plastic components, as a result of which e.g. cells can be embedded between the first structural elements 11.

[0058] The first structural elements can have a lateral resolution of about 0.5 μm to about 500 μm or of about 10 μm up to about 100 μm. As evident in FIG. 2B, a groove 11 as an exemplary first structural element has two opposite confining surfaces 112 which extend approximately perpendicularly to the first side 21 and are arranged in parallel to one another. The base of the structural element 11 forms the bottom area 111, which extends approximately parallel to the first side 21 and to the second side 22. After the production of the first structural elements, the boundary edges between the areas 112 and the first side 21 as well as between the areas 112 and the area 111 can be comparatively sharp-edged or have a burr.

[0059] FIG. 3 shows the molding tool after an optional electropolishing operation. In the electropolishing operation, an electric DC or AC voltage is applied to the molding tool 2 in an acidic electrolyte. Prior to the electropolishing operation, an optional purification step can be carried out to provide a fat-free surface of the molding tool 2. This can lead to a more uniform effect of the electropolishing operation.

[0060] Since an electric field enhancement occurs at the component edges or tips, the effect of the electropolishing operation is more intense along the edges and burrs than along the flat areas. As a result, the surface of the first structural elements 11 and/or of the first side 21 is smoothened since protruding subareas of the boundary surfaces are subject to greater removal resulting from the electropolishing operation. Furthermore, edges can be deburred or rounded, as shown by way of example along the transition 113 between the boundary surfaces 111 and 112 of the first structural element 11. Such a rounded form can be advantageous when the molding tool is cast since the soft plastic mass can penetrate more easily such rounded structures in order to completely fill them.

[0061] The period of the electropolishing operation and the removal rate are selected in such a way that undesired burrs and roughness are removed while the first structural elements 11 are maintained in the desired form.

[0062] FIG. 4 shows the molding tool 2 after the production of the second structural elements 12. In the shown embodiment, the second structural elements 12 comprise pores which cover the entire first side 21 and all boundary surfaces of the first structural elements 11. The pores 21 can be arranged in a hexagonally dense arrangement on the first side 21 of the molding tool 2.

[0063] In the shown embodiment, the pores 21 are produced by anodic oxidation of the molding tool 2. In some embodiments of the invention, the anodic oxidation can take place in a polyprotic acid, as a result of which an oxide layer is formed on the first side 21 and the first structural elements 11. The oxide layer has an intrinsic porosity which can optionally be opened further by selective etching to provide the shown open second structural elements.

[0064] If aluminum or an aluminum alloy was chosen for the molding tool 2, a layer 211 is formed during the anodic oxidation and contains aluminum oxide. Due to this, the molding tool 2 is protected against further corrosive attack. On account of the greater hardness of the oxide in comparison with the pure metal, the abrasive wear can also be reduced during casting. In some embodiments of the invention, the second structural elements 12 can have a lateral expansion and/or a depth which is smaller by a factor of at least 10 than the lateral expansion and/or the depth of the first structural elements 11. As a result, the surface of the molding tool and thus the surface of the cast component can be enlarged, e.g. to provide an active substance carrier for pharmaceutical active substances or a cell culture substrate.

[0065] The further optional method steps shown in FIGS. 5 and 6 serve to further improve the stability of the molding tool and/or to improve the product quality of the plastic component produced by means of the molding tool 2.

[0066] In method step 5, the molding tool can be tempered. In some embodiments of the invention, this can be done at a temperature between about 800° and about 1300°. A protective gas atmosphere can optionally be applied to prevent a further oxidation of the first side 21 of the molding tool 2. The temperature treatment of the molding tool 2 can effect that γ-aluminum oxide is converted into α-aluminum oxide. The α-aluminum oxide 212 can have a greater mechanical stability and/or an increased resistance to solvents, acids and/or lyes.

[0067] FIG. 6 shows the molding tool according to a further optional method step, namely the deposition of a non-stick coating 213. The non-stick coating 213 can have a lower surface energy, as a result of which the sticking of heated and thus flowable plastic mass is reduced and thus the casting of the finished plastic component is facilitated.

[0068] In some embodiments of the invention, the non-stick coating 213 can contain, or consist of, a plasma polymer which can be obtained by depositing gaseous precursors from the gas phase. The non-stick coating 213 can contain, or consist of, an organosilicon or organofluorine compound. Such coatings can be obtained e.g. from the polymerization of hexamethyldisilazane or perfluorinated hydrocarbons.

[0069] The non-stick coating can have a mean layer thickness of less than 10 nm, such that it fully covers both the first structural elements 11 and the second structural elements 12 without completely filling the structural elements and thus preventing the molding in particular of the second structural elements 12.

[0070] An injection molding method using the molding tool according to the invention is explained by means of FIGS. 7 and 8. Here FIG. 7a and FIG. 8a show an axonometric representation of the molding tool and of the plastic component. FIGS. 7b and 8b both show a cross-section through the molding tool 2 and the thus produced plastic component 3.

[0071] The molding tool 2 produced by means of the above described method can be inserted in a generally known injection molding machine. As a result, it is possible to produce plastic components having a total mass of less than 1 mg up to more than 10 kg with cycle times of some few seconds up to several minutes. For this purpose, the plastic granules are melted in generally known manner by a rotating and heated conveyor and conveyed under pressure into the injection molded form.

[0072] FIG. 7 shows how the plastic component and/or the plastic material heated above the molding temperature fills the cavities of the molding tool 2. Here, the plastic material penetrates both the first structural elements 11 and the second structural elements 12. The filling degree can be influenced via the viscosity of the liquefied raw material and the process pressure. A minor shrinkage of the plastic material during cooling can facilitate the removal of the component 3 from the molding tool 2.

[0073] FIG. 8 shows the process of removal. Here the plastic component 3 is separated from the molding tool 2. It is clear in particular from FIG. 8b that the plastic component 3 has a first structural element 31 which has been shaped by first structural elements 11 of the molding tool 2. The first structural element 31 is covered by a plurality of second structural elements 32 which were formed by the second structural elements 12 of the molding tool 2. Therefore, the plastic component and/or the plastic film 3 is both microstructured and nanostructured.

[0074] FIG. 9 shows a first embodiment of a plastic component 3. The plastic component 3 has substantially the basic shape of a plane-parallel plate, the surface of which is provided with first structural elements 31 in the form of ribs which run over the entire longitudinal extension of the plastic component 3. The entire surface is provided with second structural elements 32 and has an approximately cylindrical basic form. The second structural elements 32 also cover the first structural elements 31 such that the plastic component 3 is both microstructured and nanostructured.

[0075] FIG. 10 shows a second embodiment of a plastic component 3 according to the invention. The plastic component 3 according to the second embodiment also has first structural elements 31. In the described embodiment, the first structural elements 31 are arranged in approximately cylindrical fashion and in a uniform grid on the surface of the plastic component 3.

[0076] The entire surface of the plastic component 3 is covered by second structural elements 32, which also have an approximately cylindrical basic form. However, the second structural elements 32 are considerably smaller, i.e. by a factor of at least 10. They also cover the perpendicular surface areas of the first structural elements 31, thus taking care of an efficient enlargement of the surface of the plastic component and/or the plastic film 3.

[0077] FIG. 11 explains a device for carrying out a hot stamp process, by means of which a film web 4 can be provided continuously with a surface structure, e.g. with the structure shown in FIG. 9 or FIG. 10. For this purpose, the unstructured film web 4 is unwound from a first feed drum 51. Then, the film web 4 passes through a heating element 55, which heats at least the first side 41. The heat input can here be controlled in such a way that the second side 42 is not heated above the deformation temperature to ensure the mechanical stability of the film web 4 during the hot stamp method. However, the first side 41 is heated above the deformation temperature to render possible the plastic deformation by the molding tool 2.

[0078] For this purpose, the heating device 55 can emit electromagnetic radiation, e.g. in the infrared spectral range, in the visible spectral range or in the ultraviolet spectral range. The film web 4 can be provided with a dye, as explained below by means of FIGS. 12 to 14. As a result, a selective heating of the first side 41 becomes possible, and therefore thin films 4 having a thickness of about 10 μm to about 125 μm can also be structured in the hot stamp method without being damaged by excessive heat input.

[0079] The film web heated by the heating device 55 passes through the molding tool 2, which has the form of a cylindrical roll 26. The lateral surface 21 of the cylindrical roll 26 is provided with the structure according to the invention which has both first structural elements and second structural elements, the second structural elements being smaller than the first structural elements. The cylindrical roll 26 can optionally also be provided with an oxide layer and/or a non-stick layer, as explained above by means of FIGS. 5 and 6, in order to reduce the sticking of the plastic mass or to increase the service life of the molding tool.

[0080] In order to apply the stamp forces required for molding, a mating roll 54 can be arranged opposite the molding tool 2. The mating roll 54 can have a smooth surface in order to avoid damage and/or undesired molding of the second side 42 of the film web 4 or can optionally have the same or also another surface structured according to the method of the invention in order to be able to carry out the structuring on both sides.

[0081] If the film web 4 already cools down in contact with the molding tool 2, the resulting shrinkage can facilitate the removal of the film web 4 from the molding tool 2.

[0082] After the hot stamp process with the molding tool 2, the film web 4 can optionally pass through a cooling device 56 in order to render possible a rapid solidification below the deformation temperature and thus a mechanical stabilization of the microstructure.

[0083] Following microstructuring and cooling, the plastic film 4 can be wound onto a second feed drum 52. In order to avoid the damage of the structure, an optional protective film 43 can be applied which is unwound from a third feed drum 53 and is wound onto the second feed drum 52 together with the plastic film 4.

[0084] A process control is explained by means of FIGS. 12, 13 and 14 and permits the selective heating of the first side 41 of a plastic film 4. For this purpose, the plastic film 4 is coated with nanoparticles 45. The nanoparticles 45 have a size which is smaller than the wavelength of the electromagnetic radiation used for heating. As a result, plasmon resonances can be excited on the surface of the nanoparticles 45 which heat the nanoparticles and then heat the plastic film 4.

[0085] Since the nanoparticles 45 are only applied to the first side 41 of the plastic film 4, the heat proceeds from the first side 41 and penetrates the depth of the plastic film 4 as shown schematically by means of FIG. 13. As a result, a layer 44 bordering on the first side 41 is formed and is heated above the deformation temperature on account of the electromagnetic radiation emitted by the heating device 55. Due to this, the first side 41 can be plastically deformed and be provided with the microstructure and nanostructure according to the invention. At the same time, the opposite side of the plastic film and/or deeper layers in the volume of the film does not heat above the deformation temperature, and therefore the mechanical stability thereof is maintained during the stamp process and ensures a safe stripping of the plastic film.

[0086] According to the invention, it was found that as a result of the application of the nanoparticles 45 by means of a PVD method, individual nanoparticles 45 are arranged on the surface 41 in such a way that they are spaced apart. This serves to avoid the occurrence of agglomerates, as a result of which the plasmon resonance makes possible a light absorption in part of the electromagnetic spectrum. Light of different wavelength can penetrate the plastic film 4 without providing the plastic film 4 with an essential amount of thermal energy, thus confining the heating to the layer 44 bordering on the first side 41.

[0087] As shown in FIG. 14, the influence of the molding tool 2 and/or the stamping roll 26 changes the distribution of the nanoparticles 45. The particles can form agglomerates and/or diffuse into deeper layers of the plastic film 4, and therefore particles having different orientation are disposed in deeper layers of the plastic film due to the rearrangement of the polymer chains, as a result of which the plasmon resonance is shifted spectrally or also disappears totally. As a result, the plastic film 4 can appear to be transparent after the hot stamp process. This renders possible an optical quality check by the measurement of the absorption spectrum, and in spite of the application of a dye the method according to the invention is also suitable for plastic films 4 which shall appear to be colorless in the final application.

[0088] FIGS. 15, 16 and 17 explain the hot stamping of a plastic film 4, which contains a first layer 47 and a second layer 46. The first layer 47 can contain a polymer which has a greater hardness and/or a higher deformation temperature than the second layer. The first layer 47 and the second layer 46 can be connected to one another, e.g. by all-over lamination and/or welding. In this way, plastic films 4 having the structure according to the invention can be provided even if they consist predominantly of a material that has a great hardness or a high deformation temperature and is not accessible to a known hot stamp method. For example, the first layer 47 can consist of polyether ether ketone.

[0089] As shown in FIG. 16, the heating device 55 can emit an electromagnetic radiation which is selectively absorbed by the material of the second layer 46. As a result, the heat input into the plastic film 4 can be limited to a layer bordering on the first side 41, as described above. Therefore, the mechanical stability of the plastic film 4 is guaranteed during the hot stamp process.

[0090] As shown in FIG. 17, the second layer 46 of the plastic film 4 is cooled after the molding process initiated by the molding tool 2 and subsequently wound onto a feed roll, as already described by means of FIG. 11. Since during the entire hot stamp process the first layer 47 is not heated above the deformation temperature, thus maintaining its mechanical stability, permanent film stripping forces can be ensured, thus increasing the product quality.

[0091] The plastic components 3 and/or plastic films 4 proposed according to the invention can be used as a cell culture substrate which has a surface structure that is similar to physiological surfaces. The comparatively large first structural elements create surfaces which can be compared with natural tissue and initiate the growth and/or the attachment of cells by confining natural binding sites. The comparatively small second structural elements 12 can serve to receive functional groups, e.g. proteins. Alternatively or additionally, the second structural elements can serve as a reservoir for pharmaceutical active substances and/or nutrients, which can positively influence the cell growth.

[0092] In other embodiments of the invention, a plastic component 3 according to the invention can serve as an active substance carrier for pharmaceutical active substances. As a result, a medicinal product can be transported under controlled conditions to its site of action in a human or animal body where it is released in controlled fashion within a desired period of time. Due to this, the employed active substance amount can be reduced.

[0093] Finally, plastic components 3 having the surface structure according to the invention can be used as an implant material. The plastic components can have a load-bearing core which permits a reliable osteosynthesis. On account of the microstructure and nanostructure according to the invention, the implants according to the invention can grow rapidly and reliably into the cartilage and bone tissues, as already described by means of the cell culture substrate. As a result, the formation of fibrous capsule tissue and thus painful tissue hardening, dislocations or rejection reactions can be prevented.

[0094] A further embodiment for the molding tools and plastic components according to the invention shall be shown below. The molding tool contains an aluminum alloy which is provided with a grid of horizontal and vertical grooves by means of laser material processing. These grooves take care that ridges having equal dimension are created in the subsequent casting. Each of the grooves produced by laser material processing has a width of 50 μm and a depth of 100 μm. The distance of the individual grooves is 50 μm each. As a result, the surface of the molding tool and/or the subsequently produced plastic component is already enlarged by a factor of 5 with respect to surface defined by the geometric dimensions of the plastic component.

[0095] Cylindrical, hexagonally arranged grooves having a diameter of 100 nanometers, a depth of 500 nanometers and a pore filling factor of 50% are applied to the surface enlarged already by the microstructure by anodic oxidation using the subsequent nanostructuring operation. The pore filling factor here designates the share of the pore area in the total area. The nanostructure covers the entire surface of the molding tool, including the boundary surfaces of the microstructure produced in the preceding method step. As a result, the surface is additionally enlarged by a factor of 10, and therefore the entire enlargement of the surface by the structure according to the invention is about 50 times that of the originally planar surface.

[0096] Of course, the invention is not limited to the embodiments shown in the drawings. Therefore, the above description shall not be considered to be limiting but explanatory. The below claims should be understood such that a stated feature is present in at least one embodiment of the invention. This does not rule out the presence of further features. Insofar as the claims and the above description define “first” and “second” features, this designation serves to distinguish between two equivalent features without determining a sequence.