Pattern forming sheet, pattern manufacturing apparatus, pattern manufacturing method, and pattern manufacturing program

It is possible to implement pattern formation and pattern manufacturing that eliminate the necessity of high-cost accurate positioning. A pattern manufacturing apparatus (100) includes a controller (101) and a laser projector (102). The controller (101) controls the laser projector (102) to form a pattern on a pattern forming sheet (130) placed on a stage (140). The laser projector (102) further includes an optical engine (121). The optical engine (121) irradiates the pattern forming sheet (130) with a light beam (122). The stage (140) has a hollow structure not to obstruct the optical path of the light beam (122). The pattern forming sheet (130) includes a light-transmitting sheet material layer and a photo-curing layer applied to the sheet material layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Japanese Patent Application No. 2016-186393, filed on Sep. 26, 2016, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a pattern forming sheet, a pattern manufacturing apparatus, a pattern manufacturing method, and a pattern manufacturing program.

Description of the Related Art

In the above technical field, patent literature 1 discloses a technique of irradiating, with light, a photomask on which a circuit pattern is formed, and exposing the circuit pattern on a board.

SUMMARY OF THE INVENTION

In the technique described in the above literature, it is possible to form a pattern on a printed circuit board. However, accurate facility, apparatus, and technique are required to align a mask and a board. Thus, an end user cannot use the technique efficiently.

The present invention enables to provide a technique of solving the above-described problem. A light beam is used to form a latent image of a pattern, and a work to which a pattern forming sheet is adhered is irradiated with the light beam, thereby forming a latent image of the pattern. This enables pattern formation and pattern manufacturing that eliminate the necessity of high-cost accurate positioning.

One aspect of the present invention provides a pattern forming sheet for forming a pattern, that fits in an arbitrary work surface, comprising:

a light-transmitting sheet material layer; and

a paste-like photo-curing layer that is applied to the sheet material layer and contains a photo-curing resin.

Another aspect of the present invention provides a pattern manufacturing apparatus comprising:

a forming unit configured to form a pattern by irradiating the above-described pattern forming sheet with a light beam.

Still other aspect of the present invention provides a pattern manufacturing method comprising:

adhering the above-described pattern forming sheet to a work having an arbitrary shape;

forming a pattern by irradiating the pattern forming sheet with a light beam; and

separating a sheet material layer from the formed pattern.

Still other aspect of the present invention provides a pattern manufacturing program for causing a computer to execute a method, comprising:

forming a pattern by irradiating the above-described pattern forming sheet with a light beam.

According to the present invention, it is possible to shape a pattern on a work surface having an arbitrary shape.

DESCRIPTION OF THE EXAMPLE EMBODIMENTS

Example embodiments of the present invention will now be described in detail with reference to the drawings. It should be noted that the relative arrangement of the components, the numerical expressions and numerical values set forth in these example embodiments do not limit the scope of the present invention unless it is specifically stated otherwise.

First Example Embodiment

A pattern manufacturing apparatus100according to the first example embodiment of the present invention will be described with reference toFIGS. 1 to 7. The pattern manufacturing apparatus100is an apparatus that manufactures a pattern on an arbitrary work surface by irradiating a pattern forming sheet with a light beam.

The technical premise of this example embodiment will be described first. Note that a circuit pattern will be exemplified as a pattern. However, the technique of this example embodiment is not limited to this.

In general, a circuit pattern is determined by designing a PCB (Printed Circuit Board) using CAD (Computer Aided Design) such as PADS (Personal Automated Design System). After that, the circuit pattern is manufactured by a subcontracting maker using silk screen printing or a photoresist method. There is an increasing need to examine, using an actual product, whether the design of a circuit pattern is appropriate in addition to confirmation on the screen of a personal computer or the like in these design processes.

In a conventional circuit pattern development method, a circuit pattern printing mask to be used for screen printing or a photoresist method needs to be subcontracted and manufactured. This poses a problem that a long time and a high cost are required to actually complete a prototype. To reduce the time and cost, development of a circuit pattern is often advanced by only confirming, on the monitor of a personal computer or the like, a circuit pattern created by CAD or CAE (Computer Aided Engineering). It is, however, difficult to completely grasp a problem by confirming data of the circuit pattern displayed on the monitor. In many cases, therefore, the problem is noticed only after a prototype is manufactured. To cope with this, a mask needs to be subcontracted to manufacture a prototype, thereby increasing the time and cost to complete the prototype. Furthermore, in a method using a mask, such as screen printing, for example, it is impossible to manufacture a circuit pattern for a housing, its curved portion or corner portion, or the like.

Technique of Example Embodiment

FIG. 1is a schematic view for explaining an outline of the overall arrangement of the pattern manufacturing apparatus100according to this example embodiment. As shown inFIG. 1, the pattern manufacturing apparatus100includes a controller101and a laser projector102. The controller101controls the laser projector102to form a pattern on a pattern forming sheet130adhered to a work on a stage140. That is, the controller101forms a pattern on the pattern forming sheet130by performing irradiation with a light beam122from an optical engine121based on pattern data created by CAD. The stage140has a hollow structure not to obstruct the optical path of the light beam122, and the pattern forming sheet130placed on the stage140is irradiated with the light beam122from below. Note that creation of pattern data is not limited to CAD. For example, an application of a smartphone, CAE, or the like may be used to create pattern data. The controller101also controls the overall operation of the pattern manufacturing apparatus100. Note that the pattern forming sheet130is flexible, and can thus conform to a work having an arbitrary surface shape. The pattern forming sheet130includes a light-transmitting sheet material layer and a photo-curing layer applied to the sheet material layer.

The laser projector102includes the optical engine121. The controller101controls the laser projector102to irradiate the pattern forming sheet130with the light beam from the optical engine121.

FIG. 2Ais a view showing an outline of a pattern forming process by the pattern manufacturing apparatus100according to this example embodiment. A case in which a pattern is formed on a cylindrical glass serving as a work200, as shown in the leftmost view ofFIG. 2A, will be exemplified. The glass has a curved shape as a surface shape. As shown in the second view from the left ofFIG. 2A, the pattern forming sheet130is adhered so that a photo-curing layer132contacts the surface of the glass. As shown in the middle view ofFIG. 2A, based on the pattern data created by the controller101, irradiation with the light beam122is performed from the side of a sheet material layer131of the pattern forming sheet130adhered to the surface of the glass. The pattern forming sheet130is changed to a pattern forming sheet130′ on which a pattern210is formed in a photo-curing layer132′. The irradiation time of the light beam122changes depending on an irradiation area and laser power but falls within the range of about 1 to 20 min.

As shown in the second view from the right ofFIG. 2A, upon completion of irradiation with the light beam122, the sheet material layer131is separated. If the sheet material layer131is separated, a portion of the photo-curing layer132′, which is cured by irradiation with the light beam122, remains on the glass side, and the formed pattern210is manufactured on the surface of the glass. An uncured portion133other than the pattern210is separated together with the sheet material layer131. At this time, if the uncured portion of the photo-curing layer132remains on the surface of the glass, the remaining uncured portion is cleaned and removed, as shown in the rightmost view ofFIG. 2A. Note that if no uncured portion remains on the surface of the glass, cleaning is not necessary. The cylindrical glass has been exemplified as the work200. However, the surface shape of the work200to which the pattern forming sheet130is adhered is an arbitrary surface shape such as a flat surface, corner surface, or curved surface.

FIG. 2Bshows a plan view and a side view for explaining the arrangement of the pattern forming sheet130used in the pattern manufacturing apparatus100according to this example embodiment.

The pattern forming sheet130includes the light-transmitting sheet material layer131and the photo-curing layer132applied to the sheet material layer131. The photo-curing layer132is a paste-like layer containing a photo-curing resin. The sheet material layer131is a sheet having high light transmittance and releasability. As the sheet material layer131, a sheet made of polyolefin, polypropylene, polyethylene, polyimide, or the like, a sheet obtained by performing surface processing of a high separation performance for the above sheet, or the like is used. The present invention, however, is not limited to them. The sheet material layer131has flexibility to fit in an arbitrary shape of a work surface.

The photo-curing layer132contains a photo-curing resin. The photo-curing layer132is applied to the sheet material layer131in a size of about 37 mm in the vertical direction×about 52 mm in the horizontal direction, which corresponds to an A9 size. Note that the size of the photo-curing layer132to be applied is not limited to this. The photo-curing layer132may further contain a conductive material. By containing a conductive material in the photo-curing layer132, for example, the pattern forming sheet130can be used to form a circuit pattern. Examples of the conductive material are silver, gold, copper, platinum, lead, zinc, tin, iron, aluminum, palladium, and carbon. The present invention, however, is not limited to them.

If the pattern forming sheet130is adhered to the work200and installed, and irradiated with the light beam122from the side of the sheet material layer131, the photo-curing layer132is irradiated with the light beam122transmitted through the sheet material layer131. A portion of the photo-curing layer132, which has been irradiated with the light beam122, is cured.

The emitted light beam122is a laser having a wavelength of about 405 nm but is not limited to this. The light beam122may be, for example, a light beam having a wavelength of 200 nm to 400 nm but is not limited to this. If the sheet material layer131is separated after completion of irradiation with the light beam122, the cured portion of the photo-curing layer132remains on the side of the work200and the uncured portion is separated from the work200together with the sheet material layer131, thereby forming the pattern on the work200.

The protection sheet133for protecting the photo-curing layer132of the pattern forming sheet130may be provided. The protection sheet133is a sheet made of a material of a high separation performance, such as polytetrafluoroethylene (PTFE). The protection sheet133need only be a sheet made of a material that is readily separated while protecting the photo-curing layer132. If the protection sheet133is provided, the pattern forming sheet130can be carried and stored without damaging the photo-curing layer132.

Note that the photo-curing layer132may be mixed with ink that develops a color in accordance with the wavelength, output, and irradiation time of the light beam. Furthermore, the photo-curing layer132may be mixed with ink that develops a different color in accordance with the wavelength, output, and irradiation time of the light beam.

FIG. 2Cis a view for explaining the pattern forming sheet130used in the pattern manufacturing apparatus100and the adhesion of the pattern forming sheet130′ after light beam irradiation according to this example embodiment. The adhesion between the sheet material layer131and an uncured portion230of the photo-curing layer132is represented by F1, and the adhesion between the work200and the uncured portion230of the photo-curing layer132is represented by F2.

After irradiation with the light beam122, a portion where no pattern is formed, that is, a portion that is not irradiated with the light beam122such as a laser beam needs to be separated together with the sheet material layer131when the sheet material layer131is separated. Therefore, in this portion, instead of separating the sheet material layer131from the photo-curing layer132′, the sheet material layer131and the photo-curing layer132′ remain adhered to each other and the photo-curing layer132′ needs to be readily separated from the work200. Therefore, the adhesions desirably satisfy a relation of F2<F1.

Furthermore, the adhesion between the sheet material layer131and a cured portion220of the photo-curing layer132′ is represented by F1′ and the adhesion between the work200and the cured portion220of the photo-curing layer132′ is represented by F2′. The adhesions desirably satisfy a relation of F2′>F1′.

Furthermore, when viewed from the side of the sheet material layer131, the relation between the adhesions is desirably F1>F1′.

The photo-curing resin contained in the photo-curing layer132is, for example, an ultraviolet curing resin such as an acrylic resin (polymer acrylate), urethane resin (urethane acrylate), vinyl ester resin, or polyester-alkyd resin (epoxy acrylate). However, the photo-curing resin contained in the photo-curing layer132is not limited to this as long as a resin is cured by light beam irradiation.

If the pattern forming sheet130has the above arrangement, the releasability between the sheet material layer131and the cured portion220of the photo-curing layer132is improved, and it is possible to readily separate the sheet material layer131and the photo-curing layer132.

FIG. 2Dis a view for explaining an example of the method of applying the photo-curing layer132of the pattern forming sheet130used in the pattern manufacturing apparatus100according to this example embodiment. The photo-curing layer132is applied to the sheet material layer131by setting, in a screen printing machine250, a silk screen film251provided with an application region252. The photo-curing layer132may be applied to the sheet material layer131directly using, for example, a select roller without using the screen printing machine250.

FIG. 3is a view for explaining an example of the apparatus arrangement of the pattern manufacturing apparatus100according to this example embodiment. Note thatFIG. 3does not illustrate the controller101and the like, as appropriate. The pattern manufacturing apparatus100includes a light source unit301and a stage302. The light source unit301emits a light beam311such as a laser beam. The light source unit301forms a forming unit that forms a pattern by irradiating the pattern forming sheet130with the light beam311.

The use method of the pattern manufacturing apparatus100will be described using an example of forming a pattern on the surface of a wine glass310as the work200. First, the pattern forming sheet130is adhered to the surface of the wine glass310. The wine glass310to which the pattern forming sheet130is adhered is placed on the stage302, and the pattern forming sheet130is then irradiated with the light beam311from the light source unit301. Note that an example of manufacturing a pattern on the work200completed in advance, such as the wine glass310, has been explained. However, the use method of the pattern manufacturing apparatus100is not limited to this. For example, a channel such as a pipe may be manufactured as the work200using the pattern manufacturing apparatus100, and the pattern forming sheet130may be adhered to the manufactured channel, thereby manufacturing a pattern.

FIG. 4Ais a view for explaining an example of the arrangement of an optical engine400incorporated in the light source unit301of the pattern manufacturing apparatus100according to this example embodiment.

The optical engine400includes a light source401, a reflecting mirror402, a photodetector403, a two-dimensional MEMS (Micro Electro Mechanical System) mirror404, and an angle-of-view correction element405.

The light source401includes a semiconductor LD (Laser Diode)411, an LD holder412, a collimator lens413, and a collimator holder414. The semiconductor LD411is attached to the LD holder412, and the collimator lens413is attached to the collimator holder414. The semiconductor LD411is a laser beam oscillation element that oscillates an ultraviolet laser beam or the like. Note that the laser beam oscillation element is not limited to the semiconductor LD411and may be an LED (Light Emitting Diode).

A laser beam emitted from the semiconductor LD411is collimated by the collimator lens413, travels toward the reflecting mirror402, and is reflected by the reflecting mirror402. The photodetector403detects the power of the laser beam, and controls the illuminance of the semiconductor LD411. Then, the laser beam reflected by the reflecting mirror402enters the central portion of the two-dimensional MEMS mirror404.

The two-dimensional MEMS mirror404is a driving mirror that is driven based on an externally input control signal, and vibrates to reflect the laser beam by changing an angle in the horizontal direction (X direction) and the vertical direction (Y direction). The angle of view of the laser beam reflected by the two-dimensional MEMS mirror404is corrected by the angle-of-view correction element405. The laser beam whose angle of view has been corrected is scanned on the pattern forming sheet130and the pattern210is formed on the pattern forming sheet130. Note that the LD holder412, the collimator holder414, and the angle-of-view correction element405are installed, as needed.

FIGS. 4B and 4Care a plan view and a perspective view for explaining another example of the arrangement of an optical engine430incorporated in the light source unit301of the pattern manufacturing apparatus100according to this example embodiment.FIGS. 4B and 4Cshow the optical engine430in which the four semiconductor LDs411are arranged in a housing431. By arranging a number of semiconductor LDs411, it is possible to increase the output of the optical engine430, and implement the optical engine430according to the power. Note that the semiconductor LDs411may emit laser beams of different wavelengths and outputs. By providing a plurality of LDs that emit laser beams of different wavelengths, it is possible to select a wavelength in accordance with the purpose. By attaching a plurality of LDs that emit laser beams of the same wavelength and different beam diameters, it is possible to select a sharp or soft laser beam in an arbitrary place.

The optical engine430is an optical engine for a phenomenally downsized laser pico projector having a width of about 30 mm, a depth of about 15 mm, a height of about 7 mm, and a capacity of about 3 cc while achieving a resolution of 720p and high image quality. Note that the number of semiconductor LDs411arranged in the optical engine430is not limited to four, and one to three or five or more semiconductor LDs411may be arranged. By increasing/decreasing the number of the semiconductor LDs411, it is possible to adjust the output of the laser beam emitted from the optical engine430.

FIG. 5is a view showing the arrangement of the laser projector102including the optical engine400or430of the pattern manufacturing apparatus100according to this example embodiment. The optical engine400or430includes an LD driver511, power management circuits (PMCs)512, and a photodetector516in addition to the components described with reference toFIGS. 4A to 4C.

In addition to the optical engine121, the laser projector102includes a MEMS controller501and a laser scan display controller502. Upon receiving a pattern signal from the outside, the laser scan display controller502extracts a pixel count, a size, and the like, and transmits them to the MEMS controller501.

The PMCs512control so the LD driver511does not erroneously operate during an initial transient period, for example, a rising period or falling period. Especially, during the transient period, the output power may be lower than a necessary voltage. The LD driver511may erroneously operate due to a low voltage and/or a variation in voltage. To avoid this problem, the functional circuit block can be set in a reset state during the transient period.

FIG. 6is a block diagram showing the functional arrangement of the laser projector102including the optical engine400or430of the pattern manufacturing apparatus100according to this example embodiment. The pattern signal input to the laser scan display controller502is modulated, and sent to the LD driver511. The LD driver511controls the luminance and irradiation timing of the laser beam projected by driving the LD. The laser scan display controller502drives the MEMS controller501at the same time to vibrate the two-dimensional MEMS mirror404with respect to two axes under a predetermined condition. The power management circuit512controls the LD driver511to cause the semiconductor LD411to emit light at a predetermined voltage at a predetermined timing. The laser beam reflected by the two-dimensional MEMS mirror404through the optical systems such as the collimator lens413and the reflecting mirror402is projected on the pattern forming sheet130as a pattern forming laser beam. Note that the LD has been exemplified as a light source. The light source is not limited to the LD and may be an LED.

As described above, the MEMS scan method provides light utilization efficiency much higher than that in DLP (Digital Light Processing). Thus, the same pattern formation and shaping as those of DLP are possible with a laser of much lower power. That is, it is possible to reduce the cost and power consumption and decrease the size while achieving high accuracy. Furthermore, it is possible to narrow a laser beam (ϕ0.8 mm→ϕ0.02 mm), thereby improving the shaping accuracy. It is possible to change the irradiation area of the laser beam by changing the irradiation distance of the optical engine121. The irradiation area of the laser beam may be changed by software without changing the irradiation distance of the optical engine121.

FIG. 7is a flowchart for explaining a pattern manufacturing procedure by the pattern manufacturing apparatus100according to this example embodiment. In step S701, the pattern forming sheet130is adhered to the work200. The relation between the adhesions is as indicated by the pattern forming sheet130shown inFIG. 2C. Note that if the protection sheet133is attached to the pattern forming sheet130, the protection sheet133is detached and then the pattern forming sheet130is adhered to the work200.

In step S703, the work200to which the pattern forming sheet130is adhered is set on the stage302. In step S705, the pattern manufacturing apparatus100irradiates the pattern forming sheet130with the light beam122such as a laser beam to cure the photo-curing layer132, thereby forming a pattern. The pattern manufacturing apparatus100performs irradiation with, for example, a laser beam (light beam122) having a wavelength of 405 nm, thereby curing the pattern. Note that irradiation with the light beam122may be performed by a scan or by a method of printing the entire pattern by one irradiation operation. If irradiation with the light beam122is performed by a scan, the scan count may be one or more.

In step S707, the sheet material layer131of the pattern forming sheet130is separated. The relation between the adhesions at this time is as indicated by the pattern forming sheet130′ shown inFIG. 2C. If the sheet material layer131is separated, the cured portion220of the photo-curing layer132remains on the side of the work200, and the uncured portion230of the photo-curing layer132is separated from the work200together with the sheet material layer131. If the uncured portion230remains on the side of the work200in step S707, for example, the uncured portion230is washed away by cleaning the work200using IPA (IsoPropyl Alcohol) in step S709. Note that the uncured portion230may be cleaned by executing ultrasonic cleaning together with cleaning by IPA. This can clean the uncured portion230more reliably. Upon completion of cleaning, the work200is dried. Note that step S709is an additional step, and is executed, as needed.

By repeating the above-described steps, a three-dimensional pattern can be manufactured on the work200. That is, it is possible to manufacture a three-dimensional pattern (laminated pattern) by repeating, after the end of the above-described steps, an operation of adhering a new pattern forming sheet130onto the pattern manufactured on the work200and manufacturing a pattern a predetermined number of times. In this case, the pattern forming sheets130made of different materials may be used for the respective layers.

Furthermore, if a conductive circuit pattern of a plurality of layers is shaped as a pattern, a resist layer (resist film) may be shaped between the layers. That is, after completion of shaping of the conductive circuit pattern, a resist layer forming sheet is adhered, as the pattern forming sheet130, onto the conductive circuit pattern and a resist layer (resist pattern) is formed. On the resist layer, for example, a portion except for a portion serving as a through hole is irradiated with the light beam122and cured, and an uncured portion as the portion serving as the through hole is cleaned, thereby making it possible to shape the resist layer including a through hole. In addition to the resist layer, a layer having a waterproof function, dustproof function, and heat radiation function can be added by potting. Note that when shaping the conductive circuit pattern, the photo-curing layer132is made by mixing metal paste such as silver paste with a photo-curing resin. The present invention, however, is not limited to this. Furthermore, the pattern manufacturing apparatus100can be used as a laminating and shaping apparatus that shapes a three-dimensional laminated and shaped object by laminating a photo-curing resin, in addition to pattern shaping. That is, the pattern manufacturing apparatus100is a hybrid apparatus applicable to two applications of a pattern shaping apparatus and three-dimensional laminating and shaping apparatus.

According to this example embodiment, since the pattern forming sheet130having flexibility to fit in a work having an arbitrary shape is used, it is possible to shape a pattern on the work having the arbitrary shape. In addition, since the releasability between the sheet material layer131and the cured portion220of the photo-curing layer132is high, it is possible to readily shape a pattern on the work having the arbitrary shape by only separating the sheet material layer131after completion of light beam irradiation. Since cleaning of the uncured portion230of the photo-curing layer132after completion of light beam irradiation is not necessary, the shaping time of the pattern can be shortened. By using a plurality of pattern forming sheets130, it is possible to manufacture a laminated pattern.

Second Example Embodiment

A pattern manufacturing apparatus according to the second example embodiment of the present invention will be described with reference toFIGS. 8 and 9.FIG. 8is a view for explaining an example of the arrangement of the pattern manufacturing apparatus according to this example embodiment. Note thatFIG. 8illustrates no work to avoid the view from becoming complicated. A pattern manufacturing apparatus800according to this example embodiment is different from the first example embodiment in that a heater801is included. The remaining components and operations are the same as those in the first example embodiment. Hence, the same reference numerals denote the same components and operations, and a detailed description thereof will be omitted.

The pattern manufacturing apparatus800includes the heater801. The heater801is movable. For example, if a pattern forming sheet130is set on a stage302, the heater801is closed to heat the pattern forming sheet130. The pattern manufacturing apparatus800is used to, for example, manufacture a conductive circuit pattern using the pattern forming sheet130applied with a photo-curing layer containing a conductive photo-curing resin.

FIG. 9is a flowchart for explaining a pattern manufacturing procedure by the pattern manufacturing apparatus800according to this example embodiment. Note that the same step numbers as those inFIG. 7denote the same steps and a description thereof will be omitted. In step S901, the pattern manufacturing apparatus800heats the pattern forming sheet130. Note that step S901may be executed simultaneously with step S705.

According to this example embodiment, since the pattern manufacturing apparatus including the heater is used, it is possible to decrease the resistance value of the circuit pattern while shaping the circuit pattern, thereby shortening the shaping time. Note that instead of the circuit board, a work like the wine glass310shown inFIG. 3can be applied to the pattern manufacturing apparatus800ofFIG. 8provided with the heater. In this case, the heater801can decrease the specific volume of a photo-curing layer132within a short time by aging the sheet130on the wine glass310by heating. As a result, it is possible to quickly obtain the final shape of the photo-curing layer132on the pattern forming sheet130.

Other Example Embodiments

The present invention is applicable to a system including a plurality of devices or a single apparatus. The present invention is also applicable even when an information processing program for implementing the functions of example embodiments is supplied to the system or apparatus directly or from a remote site. Hence, the present invention also incorporates the program installed in a computer to implement the functions of the present invention by the computer, a medium storing the program, and a WWW (World Wide Web) server that causes a user to download the program. Especially, the present invention incorporates at least a non-transitory computer readable medium storing a program that causes a computer to execute processing steps included in the above-described example embodiments.