Method for manufacturing an integrated film mold

Abstract

The application discloses a manufacturing method of an integrated film mold, which comprises the following steps: (1) adopting a PC plate as a substrate, and performing one-time silk printing on the PC plate to make the PC plate adhere to a layer of light-shielding ink; (2) performing two-time silk printing on the PC plate to increase the thickness of the light-shielding ink layer and enhance the light-shielding effect, thereby obtaining a film template; (3) applying UV glue to one side of the film template on which the light-shielding ink is printed, filling the height difference area between the non-ink area and the ink area, covering a PET film sheet on the UV glue, irradiating, separating the PET film sheet from the film template after the UV glue is solidified, and making the UV glue adhere to the film template; (4) aligning and punching the texture master mold and the film template according to a required mold layout; and (5) transferring the texture on the texture master mold to the film template to obtain the film mold. The film mold prepared by the method has high precision, long service life and good light-shielding effect.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of film mold manufacturing, in particular to a manufacturing method of an integrated film mold. BACKGROUND

[0002] At present, the decoration texture of a mobile phone camera is directly transferred to the glass by a transfer process, but the transfer mold is mostly a double-layer structure: the texture film is attached to the film sheet. This attached film mold has the following technical defects: 1. The film sheet has insufficient light shielding property, and there is a local light leakage phenomenon, which reduces the yield; 2. Due to the limitation of the existing technology, the overall thickness of the mold after the film sheet is attached is generally 0.255mm, which is easy to be damaged during operation, thereby affecting the service life of the mold and increasing the production cost; 3. The double-layer structure needs an attachment process, which has high attachment precision requirements and increases the difficulty of mold manufacturing. SUMMARY

[0003] The present application aims to provide a film mold with high precision and longer service life.

[0004] To solve the above technical problems, the technical scheme adopted by the present application is:

[0005] The present application provides a manufacturing method of an integrated film mold, which comprises the following steps:

[0006] (1) PC board is used as a substrate, and the PC board is subjected to one-time silk printing to attach a layer of light shielding ink on the PC board;

[0007] (2) The PC board is subjected to two-time silk printing to increase the thickness of the light shielding ink layer and enhance the light shielding effect, thereby obtaining a film template;

[0008] (3) UV glue is applied to the side of the film template with the light shielding ink, the height difference area between the non-ink area and the ink area is filled, then a PET film sheet is covered on the UV glue, and the UV glue is cured by light irradiation. After that, the PET film sheet and the film template are separated, and the UV glue is attached to the film template;

[0009] (4) According to the required mold layout, the texture master mold and the film template are aligned and punched;

[0010] (5) The texture on the texture master mold is transferred to the film template to obtain a film mold.

[0011] Preferably, before one-time silk printing in step (1), the PC board is cleaned by a flat plate spraying cleaning line, and the cleaning line temperature is set to 40℃ and the walking speed is set to 2200mm / min.

[0012] Preferably, the first silk printing in step (1) comprises the following steps: using a glass silk printing machine to perform first silk printing on the PC board, the ink is polyvinyl chloride or phthalate, the ink ratio is: main oil 70-75%, diluent 15-20%, curing agent 10%, the silk printing ink thickness is 3-6um, the squeegee speed is 100-150mm / s, and the PC board is pre-baked in a tunnel furnace, the temperature is set to 75-80℃, and the time is 4-6min.

[0013] Preferably, the second silk printing in step (2) comprises the following steps: using a glass silk printing machine to perform second silk printing on the PC board, the ink is polyvinyl chloride or phthalate, the ink ratio is: main oil 55-65%, diluent 25-35%, curing agent 10%, the silk printing ink thickness is 3-6um, the squeegee speed is 100-150mm / s, and the PC board is pre-baked in a tunnel furnace, the temperature is set to 75-80℃, and the time is 4-6min; then the PC board is baked, the temperature is 75℃, and the time is 60min.

[0014] Preferably, the UV glue in step (3) is one of epoxy acrylate, polyurethane acrylate, polyester acrylate, and epoxy resin, the transfer parameters are: roller pressure 0.2-0.6MPa, roller speed 3-4mm / s, the light curing parameters are: UV lamp wavelength range 365-425nm, and curing energy 300-400mJ / cm 2 .

[0015] Preferably, the step (5) of transferring the texture on the texture master mold to the film template comprises the following steps: fixing the punched film template on the transfer machine table, applying UV glue to one end of the film template, the UV glue is one of epoxy acrylate, polyurethane acrylate, polyester acrylate, and epoxy resin, covering the punched texture master mold on the UV glue and fixing it, setting the transfer parameters as: roller pressure 0.1-0.2MPa, roller speed 1-3mm / s, then irradiating and curing it with UV light, the UV lamp wavelength range is 365-425nm, and the curing energy is 100-200mJ / cm2, then separating the film template from the texture master mold.

[0016] Further, after step (5), the prepared film mold is subjected to aging treatment using an ultraviolet curing machine, the energy is 500-550mJ / cm 2 , the speed is 2-2.5m / min, and the repetition number is 15-20 times.

[0017] Further, the appearance and precision of the aged film mold are checked, and a gasket is attached.

[0018] Further, after the appearance and precision inspection of the aged film mold and the pasting of the gasket, the method further comprises PVD coating the textured surface of the film mold, and the coating thickness is 30-50 nm.

[0019] Further, after the PVD coating of the textured surface of the film mold, the method further comprises appearance inspection of the coated film mold and covering of a protective film.

[0020] Due to the limitations of the existing film mold process, the film mold process is designed as an integrated type, i.e., a single-layer structure including a film template and a texture, a special ink with high shading property is used for the film shading area, and the film mold material is adjusted to PC material with suitable hardness, PC is a short name of polycarbonate, which has excellent electrical insulation, extension, dimensional stability, chemical corrosion resistance, high strength, heat resistance and cold resistance, self-extinguishing, flame retardant, non-toxic, colorable and other advantages, and the thickness of PC is optional, i.e., 0.35-0.85 mm, the overall thickness of the film mold is designed as “PC plate thickness (0.35-0.85 mm) + ink thickness (0.006-0.012 mm) + customer required texture height (0.003-0.02 mm)”, meanwhile, a punching design for the texture master mold and the film template alignment is added to ensure the precision and the consistency of the process precision, compared with the existing process, the integrated film mold can improve the shading property, prolong the service life of the mold, and ensure the precision of the film mold. BRIEF DESCRIPTION OF DRAWINGS

[0021] Fig. 1 The figure is a schematic diagram of the film template of the present application;

[0022] Fig. 2 The figure is a schematic diagram of the film template filled with UV glue of the present application;

[0023] Fig. 3 The figure is a schematic diagram of the film template filled with UV glue of the present application;

[0024] In the drawings, 10 is a PC substrate, 20 is a shading ink layer, 30 is a UV glue layer, and 40 is a texture layer. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings of the embodiments of the present application, but do not constitute a limitation on the protection scope of the present application.

[0026] Reference Figs. 1-3As shown, the application provides a one-piece film mold manufacturing method, which uses a printing process to manufacture a film template, performs precision alignment and punching on the film template and a texture master mold, transfers the texture onto the film template through a transfer process, and performs surface energy treatment on the surface after aging to manufacture a one-piece film mold.

[0027] Specifically, the one-piece film mold manufacturing method of the application comprises the following steps:

[0028] S1, using a flat plate spray cleaning line to clean the PC plate, setting the cleaning line temperature to 40 DEG C, and the walking speed to 2200mm / min;

[0029] S2, using a glass silk screen printing machine to perform one-time silk screen printing on the PC plate, the ink can be polyvinyl chloride and phthalate, etc., the ink ratio is: main oil 70-75%, diluent 15-20%, and curing agent 10%, the silk screen printing ink thickness is 3-6um, the squeegee walking speed is 100-150mm / s, and the PC plate is passed through a tunnel furnace for one-time pre-baking, the temperature is set to 75-80 DEG C, and the time is 4-6min;

[0030] S3, using a glass silk screen printing machine to perform two-time silk screen printing on the PC plate, the ink can be polyvinyl chloride and phthalate, etc., the ink ratio is: main oil 55-65%, diluent 25-35%, and curing agent 10%, the silk screen printing ink thickness is 3-6um, the squeegee walking speed is 100-150mm / s, the PC plate is passed through a tunnel furnace for one-time pre-baking, the temperature is set to 75-80 DEG C, and the time is 4-6min; and then the PC plate is subjected to solid baking, the temperature is 75 DEG C, and the time is 60min;

[0031] S4, applying UV glue to the film template prepared in S3, and bottoming the whole surface, the thickness is greater than or equal to the ink height, the height difference area between the non-ink area and the ink area is filled, wherein the UV glue is a photocuring material, which can be epoxy acrylate, polyurethane acrylate, polyester acrylate, epoxy resin, etc., a PET film piece is covered on the UV glue, the transfer parameters are set as roller pressure 0.2-0.6MPa and roller walking speed 3-4mm / s, and then the UV light is used for irradiation and curing, the UV lamp wavelength range is 365-425nm, and the curing energy is 300-400mJ / cm 2 , the film template is manually separated from the film piece;

[0032] S5, introducing the required mold layout paper into a laser cutting machine device, the file format can be dxf, raw, bmp, png, and the texture master mold and the film template are aligned and punched, and the power is 40-100W;

[0033] S6, fix the punched film template on the transfer machine table, apply UV glue on one end of the film template, the UV glue is photocuring material, which can be epoxy acrylate, polyurethane acrylate, polyester acrylate, epoxy resin, etc., cover the punched texture master mold in S5 on the UV glue and fix it, set the transfer parameters as roller pressure 0.1-0.2 MPa, roller speed 1-3 mm / s, then irradiate and cure it with UV light, the wavelength range of UV light is 365-425 nm, and the curing energy is 100-200 mJ / cm 2 , manually separate the film template from the texture master mold to obtain the film mold;

[0034] S7: use the ultraviolet curing machine to age the film mold, set the energy to 500-550 mJ / cm 2 , the speed is 2-2.5 m / min, and the repetition number is 15-20 times;

[0035] S8, check the appearance and precision of the film mold, and paste the gasket;

[0036] S9, PVD coating film on the texture surface of the film mold, evaporate oxide such as SiO2 and TiO2, and the thickness is 3-50 nm;

[0037] S10, appearance inspection of the film mold, and cover the protective film.

[0038] The above is the preferred embodiment of the present application, it should be noted that for those skilled in the art, without departing from the principles of the present application, can make a number of improvements and refinements, these improvements and refinements also considered as the protection scope of the present application.

Claims

1. A method of making an integrated film mold, characterized by, The method comprises the following steps: (1) using a PC board as a substrate, and performing one-time silk printing on the PC board to attach a layer of light-shielding ink on the PC board; (2) performing two-time silk printing on the PC board to increase the thickness of the light-shielding ink layer and enhance the light-shielding effect, thereby obtaining a film template; (3) applying UV glue to one side of the film template on which the light-shielding ink is printed, filling the area with a height difference between the non-ink area and the ink area, then covering a PET film on the UV glue, irradiating, curing the UV glue, and separating the PET film from the film template, so that the UV glue is attached to the film template; (4) according to the required die layout, aligning and punching the texture master mold and the film template; (5) transferring the texture on the texture master mold to the film template to obtain a film die.

2. The method of claim 1, wherein: Before the one-time silk printing in step (1), the PC board is cleaned by using a flat plate spray cleaning line, and the cleaning line temperature is set to 40℃ and the walking speed is set to 2200mm / min.

3. The method of claim 1, wherein: The one-time silk printing in step (1) comprises the following steps: using a glass silk printing machine to perform one-time silk printing on the PC board, the ink is polyvinyl chloride ink or phthalate ink, the ink ratio is: main oil 70-75%, diluent 15-20%, curing agent 10%, the silk printing ink thickness is 3-6um, the squeegee walking speed is 100-150mm / s, and the silk printing ink is pre-baked in a tunnel furnace, the temperature is set to 75-80℃, and the time is set to 4-6min.

4. The method of claim 1, wherein: The two-time silk printing in step (2) comprises the following steps: using a glass silk printing machine to perform two-time silk printing on the PC board, the ink is polyvinyl chloride ink or phthalate ink, the ink ratio is: main oil 55-65%, diluent 25-35%, curing agent 10%, the silk printing ink thickness is 3-6um, the squeegee walking speed is 100-150mm / s, and the silk printing ink is pre-baked in a tunnel furnace, the temperature is set to 75-80℃, and the time is set to 4-6min; then the PC board is solid-baked at a temperature of 75℃ for 60min. The UV glue in step (3) is one of epoxy acrylate, polyurethane acrylate, polyester acrylate and epoxy resin, the transfer parameters are: roller pressure 0.2-0.6MPa, roller walking speed 3-4mm / s, the light curing parameters are: UV lamp wavelength range 365-425nm, and curing energy 300-400mJ / cm2.

5. The method of claim 1, wherein: In step (5), the texture on the texture master mold is transferred to the film template, which comprises the following steps: fixing the punched film template on the transfer machine table, applying UV glue to one end of the film template, the UV glue is one of epoxy acrylate, polyurethane acrylate, polyester acrylate and epoxy resin, covering the punched texture master mold on the UV glue and fixing it, setting the transfer parameters as follows: roller pressure 0.1-0.2MPa, roller walking speed 1-3mm / s, then irradiating and curing it with UV light, the UV lamp wavelength range is 365-425nm, and the curing energy is 100-200mJ / cm2, then separating the film template from the texture master mold.

6. The method of claim 1, wherein: ​ 7. The method of claim 1, wherein: After step (5), the prepared film mold is subjected to aging treatment using a UV curing machine, the energy is set to 500-550 mJ / cm2, the walking speed is set to 2-2.5 m / min, and the number of repetitions is set to 15-20 times.

8. The method of claim 7, wherein: The appearance and precision of the aged film mold are checked, and the film mold is pasted with gaskets.

9. The method of claim 8, wherein: After the appearance and precision of the aged film mold are checked, and the film mold is pasted with gaskets, the textured surface of the film mold is subjected to PVD coating, and the coating thickness is 30-50 nm.

10. The method of claim 9, wherein: After the textured surface of the film mold is subjected to PVD coating, the appearance of the coated film mold is checked, and a protective film is coated.

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