Manufacturing method for original mold of laminated total prism reflecting material

Abstract

The invention discloses a method for manufacturing an original mold of a laminated total prism reflecting material, which comprises the following steps of: laminating metal sheets and clamping the metal sheets on an inclined surface of a wedge-shaped clamp by using the wedge-shaped clamp, keeping a planing path of a horizontal plane by using a V-shaped cutter, and planing the metal sheets in two mutually vertical directions to form a total prism pyramid array structure. By means of the device, the planing workload is reduced, the production efficiency is improved, the metal sheets are clamped and kept consistent, and operation errors caused by repositioning and tool setting due to overturning of the metal sheets are avoided. And meanwhile, planing is conducted on the horizontal plane, step lines are avoided, the number of burrs on the planed surface is small, the cleanliness is high, the machining quality of the pyramid surface is improved, the stability of the cutter is higher, and abrasion of the cutter is reduced.

Description

Technical Field

[0001] This invention belongs to the field of reflective material manufacturing technology, and specifically relates to a method for manufacturing an original mold for a stacked full-prism reflective material. Background Technology

[0002] Full-prism reflective film is currently the most advanced reflective material technology in the world. Compared with triangular pyramid reflective materials, full-prism reduces the dead zone area (i.e., the area of ​​ineffective reflected light) and increases the unit array density, thereby improving the retroreflection coefficient. Currently, there are several documented methods for processing full prisms, such as CN105252238A, which describes a method for making original molds for full prism reflective materials. This method achieves precision machining of the side of the sheet, solving the accuracy problem of the three sides of the full prism. However, due to insufficient rigidity, the metal sheet is prone to deformation when machining a single sheet in the direction perpendicular to the edge, resulting in burrs on the surface. Furthermore, this method requires machining V-grooves along the inclined plane, requiring two-axis linkage. That is, during horizontal cutting, the tool needs to be lifted along the inclined plane simultaneously. In other words, the oblique shape is formed by alternating horizontal (x) and vertical (y) paths. Essentially, the two axes are interpolated by straight line segments, meaning the oblique line is essentially formed by countless small segments of alternating horizontal and vertical straight lines. This results in poor surface roughness, easy formation of step marks, unstable cutting load, rapid tool wear, and easy chipping of the cutting edge.

[0003] For example, CN109500544A describes a method for manufacturing microstructure molds using a thin-thickness interleaved stacking method. While this improves the straightness of the metal sheets in the angular direction, enhances the sheet fit, and increases the sheet rigidity, the two tilting and flattening operations of the thin-thickness interleaved stacking increase the workload of cutting. Moreover, after the thin sheets are flipped left and right and the thick sheets are flipped up and down, repositioning is required during cutting. Because the reflective material's full prism structure is extremely fine, the accuracy of repeated positioning and flipping angle positioning is extremely high. If multiple stacking and repositioning are performed, not only will the difficulty increase, but the cumulative error will also increase exponentially with the number of times. Summary of the Invention

[0004] To address the problem of fabricating full-prism molds by cutting micro-precision array structures using stacked and clamped metal sheets in existing technologies, this invention proposes a method for fabricating a stacked full-prism reflective material original mold. Utilizing a wedge-shaped clamp, metal sheets are stacked and clamped onto the inclined surface of the wedge. A V-shaped cutter maintains a horizontal planing path, planing the metal sheets in two mutually perpendicular directions to create a full-prism pyramidal array structure. This method not only reduces planing workload and improves production efficiency but also ensures consistent clamping of the metal sheets, avoiding operational errors caused by repositioning the cutter due to flipping the metal sheets. Furthermore, planing on a horizontal surface avoids step marks, resulting in fewer burrs, higher cleanliness, improved pyramidal surface finish, and enhanced tool stability, reducing tool wear.

[0005] The present invention adopts the following technical solution.

[0006] A method for manufacturing a primary mold for a stacked full-prism reflective material includes the following steps: Step 1. Stack extremely thin metal sheets of equal length, height and thickness into a metal block and clamp it to the inclined surface of the wedge-shaped fixture. Step 2. Using a single-angle vertical V-shaped cutter, V-grooves are machined on one side of the metal sheet along the length direction to create V-grooves between the pentagonal sides of the array full prism unit pyramid. Using a double-angle right-angle V-shaped cutter, V-grooves are machined at the same spacing along the thickness direction of the metal sheet to create V-grooves between the quadrilateral sides of the array full prism unit pyramid. Step 3. Repeat step 2 until each metal sheet has a full prism unit pyramidal array, and finally make a stacked full prism reflective material original mold with pyramidal array structure; During the machining processes in steps 2 and 3, the tool position is always horizontal when planing the V-groove; The full prism unit pyramid formed in steps 2 and 3 has one pentagonal lateral face and two quadrilateral lateral faces. The three lateral faces of the pyramid are perpendicular to each other in pairs, forming a cubic corner.

[0007] Furthermore, in step 1, the thickness of the metal sheet is 0.05 mm to 0.5 mm, and the angle between the inclined surface of the wedge fixture and the horizontal plane is 30° to 45°, preferably 35.25°.

[0008] Furthermore, the single-angle vertical V-shaped cutter used in step 2 has an angle on only one side, that is, the angle on one side is 0°, and the angle on the other side is the same as the angle between the inclined surface of the wedge fixture and the horizontal plane, which is 30° to 45°, preferably 35.25°.

[0009] Furthermore, the double-tilt right-angle V-shaped blade used in step 2 has tilt angles on both sides, with the sum of the tilt angles being 90°. The tilt angles on both sides can be the same or different, with the tilt angles ranging from 30° to 60°, preferably 45° with the same tilt angle.

[0010] Furthermore, steps 2 and 3 involve planing the stacked metal sheets one by one, from the lower metal sheet to the higher metal sheet.

[0011] Furthermore, the stacked metal sheets in the original mold of the full prism reflective material completed in step 3 can be flipped to form a back-to-back full prism pyramid array structure reflective material original mold that is more conducive to the production of subsequent processes.

[0012] One or more technical solutions provided in this invention have at least the following technical effects or advantages: Metal sheets can be processed into shape by stacking them only once, avoiding the defects of processing single metal sheets, which are not rigid enough and are easily deformed. This results in inconsistent overall quality after processing individual metal sheets and then stacking them, affecting the final surface quality of the microstructure. This invention not only helps to improve the rigidity of metal sheets and maintain the consistency of metal sheets and the integrity of the overall microstructure by stacking them into metal blocks, but also improves the surface quality of microstructure processing and increases the production efficiency of microstructure molds.

[0013] Compared to planing a full prism structure by cutting a solid metal block, which requires the tool to run in a zigzag pattern in the longitudinal direction and causes significant damage to the tool, this invention avoids the need for the tool to run in a zigzag pattern in the longitudinal direction during planing by fixing a metal block made of multiple thin metal sheets onto the inclined surface of a wedge-shaped fixture. This reduces tool wear, lowers the probability of tool tip breakage, and extends the tool's service life.

[0014] When machining V-grooves in any direction, the tool only needs to be planed along the horizontal plane. This eliminates the need for oblique longitudinal movement, which would increase the amount of planing work. Furthermore, the tool has strong rigidity and stability, and the cone surface does not produce step marks or burrs caused by tool lifting. The surface is clean, which greatly improves the quality of micro-fine and ultra-precision surface machining.

[0015] The metal sheets do not need to be flipped up and down or left and right during the processing. The only requirement is that the stacked metal sheets are flipped to form a pyramidal back-to-back full prism mold when the finished product needs to be flipped to provide more favorable conditions for the subsequent process. This not only greatly reduces the difficulty of multiple flipping and stacking, but also avoids the cumulative error caused by multiple stacking, thereby improving production efficiency. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings of the embodiments will be briefly described below. Obviously, the drawings described below only relate to some embodiments of this disclosure and are not intended to limit this disclosure.

[0017] Figure 1 This is a three-dimensional view of the stacked metal sheets fixed to the inclined surface of the wedge-shaped clamp according to the present invention.

[0018] Figure 2 This is a schematic diagram of the V-shaped groove between the pentagonal sides of the pyramidal array of the first embodiment of the present invention.

[0019] Figure 3 This is a perspective view of the V-shaped groove structure between the pentagonal lateral faces of the array full prism unit pyramid processed according to Embodiment 1 of the present invention.

[0020] Figure 4 This is a schematic diagram of the V-shaped groove between the quadrilateral sides of the pyramidal array of the present invention, which is processed according to an embodiment of the present invention.

[0021] Figure 5 This is a perspective view of the V-shaped groove structure between the quadrilateral sides of an array full prism unit pyramid formed by processing in Embodiment 1 of the present invention.

[0022] Figure 6 This is a perspective view of the array full-prism pyramid structure processed according to Embodiments 1 and 2 of the present invention.

[0023] Figure 7 This is a top view of the completed array full-prism pyramid structure in Examples 1 and 2 of the present invention.

[0024] Figure 8 This is a three-dimensional view of the original mold of the stacked full-prism reflective material of the present invention.

[0025] Figure 9 This is a top view of the original mold for the stacked full-prism reflective material of this invention.

[0026] Figure 10 This is a schematic diagram of the V-shaped groove between the quadrilateral sides of the pyramidal array of the prism unit processed in Embodiment 2 of the present invention.

[0027] Figure 11 This is a perspective view of the V-shaped groove structure between the quadrilateral sides of the array full prism unit pyramid formed by processing in Embodiment 2 of the present invention.

[0028] Figure 12 This is a perspective view of the V-shaped groove structure between the quadrilateral sides of the array full prism unit pyramid processed according to Embodiment 2 of the present invention.

[0029] Figure 13This is a top view of the V-shaped groove structure between the quadrilateral sides of the array full prism unit pyramid processed according to Embodiment 2 of the present invention.

[0030] Figure 14 This is a side view of the V-shaped groove structure between the quadrilateral sides of the array full prism unit pyramid processed according to Embodiment 2 of the present invention.

[0031] Figure 15 This is a schematic diagram of the V-shaped groove between the pentagonal sides of the pyramidal array of the prism unit processed in Embodiment 2 of the present invention.

[0032] Figure 16 This is a perspective view of the original mold (back-to-back pyramidal) of the stacked full-prism reflective material of this invention.

[0033] Figure 17 This is a top view of the original mold (back-to-back pyramidal) of the stacked full-prism reflective material of the present invention. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the described embodiments of this disclosure without creative effort are within the scope of protection of this invention.

[0035] In this invention, unless otherwise specified or the meaning may be derived differently from the context, the terms have the meaning as commonly understood in the art.

[0036] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the instruction manual and specific implementation methods.

[0037] Combination Figures 1 to 17 As shown, the method includes the following steps: Example 1:

[0038] Step 1. Stack metal sheets of equal length, height, and thickness (0.05 mm) into a metal block and fix it on the inclined surface of a wedge-shaped clamp with an angle of 30° between the inclined surface and the horizontal plane. Figure 1 As shown; Step 2. Reference Figure 2Using a 30° single-angle vertical V-shaped cutter (the single-angle vertical V-shaped cutter has an angle on only one side, i.e., one side has an angle of 0°, and the other side has an angle of 30°, the same as the angle between the inclined surface of the wedge fixture and the horizontal plane), the stacked metal sheets are planed along one edge along their length, from the lower metal sheet to the higher metal sheet, to create V-shaped grooves between the pentagonal lateral surfaces of the array full-prism unit pyramid. Figure 3 As shown; Step 3. Reference Figure 4 Using a 30° / 60° double-angle right-angle V-cutter (the double-angle right-angle V-cutter has angles on both sides, with the sum of the angles being 90°, and one side having an angle of 30°), V-grooves are machined between the quadrilateral sides of the array full-prism unit pyramid by planing along the thickness direction of the same metal sheet at the same interval. Figure 5 As shown; Step 4. Repeat the processing method in Step 3, planing each stacked metal sheet at the same spacing in the thickness direction, from the lower metal sheet to the higher metal sheet, to produce an array of full-prism pyramidal structures. Figure 6 As shown, its top view is as follows Figure 7 As shown; Step 5. Remove the wedge-shaped clamp and take the planed, stacked metal sheet with an array of full-prismatic pyramidal structures from the inclined surface of the wedge-shaped clamp, as shown in the image. Figure 8 As shown, its top view is as follows Figure 9 As shown, the original mold for the stacked full-prism reflective material has been completed.

[0039] Crucially, during steps 2, 3, and 4, the tool is always positioned on a horizontal plane when planing the V-groove. The full prism unit pyramid formed in steps 3 and 4 has one pentagonal lateral face and two quadrilateral lateral faces. The three lateral faces of the pyramid are perpendicular to each other in pairs, forming a cubic corner. Example 2:

[0040] Step 1. Stack metal sheets of equal length, height, and thickness (0.5 mm) into a metal block and fix it on the inclined surface of a wedge-shaped clamp with an angle of 45° between the inclined surface and the horizontal plane. Figure 1 As shown; Step 2. Reference Figure 10 Using a 45° / 45° double-angle right-angle V-cutter (the double-angle right-angle V-cutter has angles on both sides, the sum of the angles is 90°, and the angles are the same, 45°), V-shaped grooves are machined between the quadrilateral sides of the array full-prism unit pyramid by planing along the thickness direction of the same metal sheet at the same interval. Figure 11 As shown; Step 3. Repeat the processing method of Step 2, from the metal sheet at the lower position to the metal sheet at the higher position, and perform planing at the same spacing in the thickness direction on each stacked metal sheet to create V-shaped grooves between the quadrilateral sides of the array full-prism unit pyramids on each metal sheet. Figure 12 As shown, its top view is as follows Figure 13 As shown, its side view is as follows Figure 14 As shown; Step 4. Reference Figure 15 Using a 45° single-angle vertical V-shaped cutter (the single-angle vertical V-shaped cutter has an angle on only one side, i.e., one side has an angle of 0°, and the other side has an angle of 45°, the same as the angle between the inclined surface of the wedge fixture and the horizontal plane), the stacked metal sheets are planed along one edge along their length, from the lower metal sheet to the higher metal sheet, to produce an array of full-prism pyramidal structures. Figure 6 As shown, its top view is as follows Figure 7 As shown; Step 5. Remove the wedge-shaped clamp and take the planed, stacked metal sheet with an array of full-prismatic pyramidal structures from the inclined surface of the wedge-shaped clamp, as shown in the image. Figure 8 As shown, its top view is as follows Figure 9 As shown, the original mold for the stacked full-prism reflective material has been completed.

[0041] Crucially, during steps 2, 3, and 4, when planing the V-groove, the tool is always positioned on a horizontal plane. The full prism unit pyramid formed in step 4 has one pentagonal lateral face and two quadrilateral lateral faces. The three lateral faces of the pyramid are perpendicular to each other, forming a cubic corner.

[0042] As needed, the stacked metal sheets can be flipped using the original mold of the stacked full-prism reflective material completed in Example 1 or Example 2, forming a pyramidal pyramidal array structure of the reflective material original mold that is more conducive to subsequent production processes. Figure 16 As shown, its top view is as follows Figure 17 As shown.

[0043] Exemplary embodiments of this disclosure have been specifically shown and described above. It should be understood that this disclosure is not limited to the detailed structures, arrangements, or implementations described herein; rather, this disclosure is intended to cover various modifications and equivalent arrangements contained within the spirit and scope of the appended claims.

Claims

1. A method for manufacturing an original mold for a stacked full-prism reflective material, characterized in that, The method includes the following steps: Step 1. Stack extremely thin metal sheets of equal length, height and thickness into a metal block and clamp it to the inclined surface of the wedge-shaped fixture. Step 2. Using a single-angle vertical V-shaped cutter, V-grooves are machined on one side of the metal sheet along the length direction to create V-grooves between the pentagonal sides of the array full prism unit pyramid. Using a double-angle right-angle V-shaped cutter, V-grooves are machined at the same spacing along the thickness direction of the metal sheet to create V-grooves between the quadrilateral sides of the array full prism unit pyramid. Step 3. Repeat step 2 until each metal sheet has a full prism unit pyramidal array, and finally make a stacked full prism reflective material original mold with pyramidal array structure; During the machining processes in steps 2 and 3, the tool position is always horizontal when planing the V-groove. The full prism unit pyramid formed in steps 2 and 3 has one pentagonal lateral face and two quadrilateral lateral faces. The three lateral faces of the pyramid are perpendicular to each other in pairs, forming a cubic corner.

2. The method for manufacturing the original mold of the stacked full-prism reflective material according to claim 1, characterized in that, In step 1, the thickness of the metal sheet is 0.05 mm to 0.5 mm, and the angle between the inclined surface of the wedge fixture and the horizontal plane is 30° to 45°.

3. The method for manufacturing the original mold of the stacked full-prism reflective material according to claim 1, characterized in that, The single-angle vertical V-shaped cutter used in step 2 has an angle on only one side, that is, the angle on one side is 0°, and the angle on the other side is the same as the angle between the inclined surface of the wedge fixture and the horizontal plane, which is 30° to 45°.

4. The method for manufacturing the original mold of the stacked full-prism reflective material according to claim 1, characterized in that, The double-angle right-angle V-shaped blade used in step 2 has angles on both sides, and the sum of the angles is 90°. The angles on both sides can be the same or different, and the angles range from 30° to 60°.

5. The method for manufacturing the original mold of the stacked full-prism reflective material according to claim 1, characterized in that, The processing steps 2 and 3 involve planing the stacked metal sheets one by one, from the lower metal sheet to the higher metal sheet.

6. The method for manufacturing the original mold of the stacked full-prism reflective material according to claim 1, characterized in that, Also includes: Step 4. In the original mold of the stacked full prism reflective material completed in Step 3, the stacked metal sheets are flipped to form a back-to-back full prism pyramid array structure reflective material original mold that is more conducive to the production of subsequent processes.

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