A method of creating a texture mold by encoding a puzzle

Abstract

The present application relates to the technical field of mold manufacturing, and particularly relates to a method for generating a texture mold through coded jigsaw, comprising a drawing generation step and a mold processing step; the present application solves the problems of traditional texture mold manufacturing, such as seams in pattern splicing, the need for manual replacement of grating structures, and the inability to prepare large-area and continuously changing angle and frequency texture structures, by pre-splicing a plurality of grating structure drawings in a coded jigsaw manner, and achieves the effect of forming a plurality of texture structures on one mold; in addition, the present application not only prepares a plurality of texture structures with continuously changing angle and frequency, but also avoids film splicing and manual replacement of grating structures, achieves seamless splicing, simplifies the operation steps, improves the yield, reduces the processing cost, and improves the production efficiency.

Description

Technical Field

[0001] This invention relates to the field of mold manufacturing technology, and in particular to a method for generating textured molds by encoding puzzle patterns. Background Technology

[0002] In the existing process of manufacturing texture molds, it is generally necessary to first prepare multiple microstructure molds, and then splice them together with films. At the same time as splicing, patterns also need to be reserved so that multiple structures can be combined onto a single mold. This method is not only time-consuming, but also produces gaps at the splicing points, and is prone to problems such as mold scratches, dirt, and scrapping during the splicing process.

[0003] In addition, such as Figure 1 As shown, existing texture mold manufacturing requires manually changing the grating structure on the exposure machine and then combining multiple structures on the mold. This method is not only inefficient but also prone to errors.

[0004] Moreover, traditional mechanical gratings cannot produce texture structures with large areas and continuously changing angles and frequencies, such as Fresnel lenses. Summary of the Invention

[0005] This invention provides a method for generating texture molds by encoding and assembling patterns. The technical problem it solves is that traditional texture mold manufacturing has gaps when splicing patterns, requires manual replacement of grating structures, and cannot produce large-area texture structures with continuously changing angles and frequencies.

[0006] To address the above technical problems, this invention provides a method for generating texture molds through encoded mosaics, including a file generation step and a mold processing step, wherein the file generation step includes:

[0007] S1. Draw the grayscale cell diagram and grayscale path diagram;

[0008] S2. Modify the grayscale unit diagram according to design requirements to obtain various grating structure diagrams;

[0009] S3. Use the raster structure map to identify each pixel value in the grayscale path map, and generate an image file by encoding and mosaicking;

[0010] This technical solution uses software encoding to pre-process multiple raster structure images, thus reducing the number of subsequent processes, lowering costs, and avoiding film splicing. At the same time, this technical solution uses encoded splicing to create large-area texture structures with continuously changing angles and frequencies, thereby enabling multiple structures to exist on a single mold and presenting diverse texture visual effects.

[0011] In a further embodiment, the gray scale unit graph and the gray scale path graph containing gray scale pixels are obtained by software drawing with gray scale attributes;

[0012] The color mode of the gray scale unit graph is a gray scale mode, and the color mode of the gray scale path graph is a gray scale mode or an RGB mode;

[0013] The gray scale unit graph and the gray scale path graph can be obtained by drawing with various software with gray scale bitmap attributes, and the drawing software has better compatibility through the coding and splicing method. The gray scale path graph and various gray scale unit graphs are spliced by coding to generate various structure files, which is simple in operation and improves the yield.

[0014] In a further embodiment, the step S2 specifically comprises: changing the gray scale pixels of the gray scale unit graph according to the specific generated texture effect requirement to obtain various digital raster structure graphs containing different line numbers and high gray scale topography;

[0015] Specifically, the raster structure in the raster structure graph includes a planar raster structure and a 3D raster structure; the planar and 3D raster structures both include a slit raster structure and a blazed raster structure.

[0016] The gray scale pixels of the gray scale unit graph are changed by coding to obtain different digital raster structure graphs, which not only reduces the manual operation process, but also can obtain various raster structures. In addition, each raster structure graph can be customized in the present technical solution, and different raster structures do not affect each other. The raster structure can be divided into a planar raster structure and a 3D raster structure in structure, and also includes a planar and 3D combined raster structure, so that various different texture structures can be formed on one mold.

[0017] In a further embodiment, the step S3 comprises the following steps:

[0018] S31. The gray scale unit graph cyclically identifies each pixel value in the gray scale path graph;

[0019] S32. It is judged whether the pixel value is 0, if yes, the gray scale path graph is filled; if not, the raster structure is rotated and overlaid first, and then the gray scale path graph is filled;

[0020] S33. A file containing various raster structures and various rotation angles is generated by coding and splicing;

[0021] Specifically, the gray scale path graph contains different pixel values;

[0022] The pixel value should include the following two attributes:

[0023] (a) specifying the grating structure to be used;

[0024] (b) specifying the rotation angle of the grating structure, which is 0-360°;

[0025] The technical solution can be coded and assembled by MATLAB or C language to obtain a texture structure capable of continuously changing the angle and frequency. In addition, the gray scale unit graph changed by the technical solution contains a plurality of different grating structure graphs. The required grating structure graph can be selected according to actual needs to identify and fill all pixel values in the gray scale path graph, which not only enriches the types of texture structures, but also generates a texture of any structure according to user needs, while reducing labor costs and shortening the production cycle.

[0026] In further embodiments, the mold processing step comprises:

[0027] S4. Exposure, development and transfer operation is performed on the drawing file to obtain a texture mold;

[0028] S5. Transfer and curing operations are performed on the texture mold to obtain a transfer mold;

[0029] The technical solution can not only enrich the texture structure by coding and assembling, but also avoid manual replacement of the grating in the exposure process, thereby simplifying the operation steps, saving preparation time, reducing production costs, and improving the yield.

[0030] In further embodiments, the step S4 comprises the following steps:

[0031] S41. The exposure machine receives the drawing file and converts the gray scale value in the drawing file into different energy levels, and then the exposure machine exposes the different energy levels on the glass substrate coated with photoresist;

[0032] S42. After the exposed drawing file is developed by the developing machine, the glass substrate with different texture structures is obtained, and then the transfer station transfers the glass substrate to obtain the texture mold;

[0033] Specifically, in the step S42, the texture structure includes a planar texture structure, a 3D stereoscopic texture structure, and a texture structure combining planar and 3D stereoscopic structures.

[0034] The technical scheme mainly adopts gray scale exposure mode to expose the drawing file, so that a texture mold with various texture structures is obtained; compared with the prior art, the technical scheme avoids manual replacement of the grating in the exposure process, simplifies the subsequent processing process, improves the yield, and improves the production rate of the mold.

[0035] In a further embodiment, when the texture structure on the glass substrate is only the planar texture structure, the glass substrate must be pre-baked and cured before the transfer operation.

[0036] The technical scheme pre-bakes and cures the glass substrate according to the texture structure after development, and generally does not pre-bake and cure if it is a 3D texture structure or a combination of planar and 3D texture structure, in order to prevent the photoresist from deforming and affecting the texture structure and optical effect. The technical scheme differentially processes the texture structure according to the actual situation, improves the pass rate of the mold, and improves the quality of the mold. BRIEF DESCRIPTION OF DRAWINGS

[0037] Figure 1 is a schematic diagram of the dot array exposure mode provided by the background art of the present application;

[0038] Figure 2 is a drawing file generation step schematic diagram of a method for generating a texture mold by coding puzzle provided by an embodiment of the present application;

[0039] Figure 3 is a simple schematic diagram of a grating structure provided by an embodiment of the present application;

[0040] Figure 4 is a schematic diagram of a conventional splicing mode of a grating structure provided by an embodiment of the present application;

[0041] Figure 5 is a schematic diagram of a coding splicing mode of a method for generating a texture mold by coding puzzle provided by an embodiment of the present application;

[0042] Figure 6 is a simple schematic diagram of a microstructure after exposure and development provided by an embodiment of the present application;

[0043] Figure 7 is a schematic diagram of a texture structure spliced by a mold processing step provided by an embodiment of the present application. DETAILED DESCRIPTION

[0044] The embodiments of the present application are described in detail below with reference to the drawings, the embodiments are only for illustrative purposes and should not be construed as limiting the present application, the accompanying drawings are only for reference and illustration and do not constitute a limitation on the scope of patent protection of the present application, because many changes can be made to the present application without departing from the spirit and scope of the present application.

[0045] In view of the problems of the traditional texture mold manufacturing, such as seams in pattern splicing, manual replacement of grating structures and inability to prepare large-area and continuously variable angle and frequency texture structures, the embodiment of the present application provides a method for generating a texture mold by coding puzzle, which comprises a file generation step and a mold processing step, as shown in Figure 2 The file generation step comprises:

[0046] S1. Drawing a gray scale unit graph and a gray scale path graph;

[0047] S2. Changing the gray scale unit graph according to design requirements to obtain a plurality of grating structure graphs;

[0048] S3. Identifying each pixel value in the gray scale path graph with the grating structure graph to generate a file by coding puzzle.

[0049] In the embodiment, the gray scale unit graph and the gray scale path graph are drawn by a drawing tool with a gray scale bitmap attribute, such as PHOTOSHOP, CORELDRAW and MATLAB.

[0050] The gray scale unit graph is mainly composed of gray scale pixels.

[0051] The gray scale path graph is mainly composed of 8-bit gray scale mode pixels, and can also be composed of 16-bit, 32-bit gray scale mode or RGB mode.

[0052] In the embodiment, the gray scale unit graph automatically identifies and fills each pixel in the gray scale path graph, which is convenient and fast, reduces manual operation and reduces cost.

[0053] Meanwhile, the embodiment prepares a continuously variable angle and frequency texture structure by coding puzzle, so that multiple structures exist on one mold at the same time, a diversified texture visual effect is presented, and the coding splicing method in the embodiment can make the compatibility of the drawing software stronger.

[0054] In the embodiment of the present application, the step S2 is specifically: changing the gray scale pixels of the gray scale unit graph according to the specific generated texture effect requirement to obtain a plurality of digital grating structure graphs, and the grating structure comprises gray scale topographies with different line numbers and different heights.

[0055] In this embodiment, the grating structure in the grating structure diagram includes a planar grating structure and a 3D grating structure. For ease of understanding, Figure 3 Several planar / 3D grating structures are briefly listed, such as: A-unit, B-unit, C-unit, D-unit, and E-Fresnel; in practical applications, the grating structure may also include a combination of planar and 3D grating structures; the planar and 3D grating structures include slit grating structures and blazed grating structures, such as: planar slit gratings and 3D blazed gratings.

[0056] In this embodiment, step S3 includes the following steps:

[0057] S31. The grayscale unit map cyclically identifies each pixel value in the grayscale path map;

[0058] S32. Determine whether the pixel value is 0. If yes, fill the grayscale path map; if no, first perform rotation and overlay operations on the raster structure, and then fill the grayscale path map.

[0059] S33. Generate an image file containing multiple raster structures and multiple rotation angles by encoding the puzzle.

[0060] like Figure 4 As shown, the embodiments of the present invention provide simple examples of several conventional splicing methods for grating structures (A unit, B unit, etc.).

[0061] In this embodiment, the grayscale path map includes different pixel values;

[0062] like Figure 5 As shown, the pixel value should include the following two attributes:

[0063] (a) Specify the grating structure to be used;

[0064] (b) Specify the rotation angle of the grating structure, wherein the rotation angle is 0 to 360°.

[0065] In this embodiment of the invention, the image is coded and pieced together using encoding software, such as MATLAB or C language. At least three elements are required in the image collage process: the raster structure diagram, the grayscale path diagram, and the rotation command. The raster structure diagram and the grayscale path diagram can be customized, and the rotation command can instruct the raster structure diagram to rotate at a customized angle from 0 to 360°.

[0066] The embodiment of the present application encodes and combines multiple grating structure patterns, does not need to perform film splicing, does not cause appearance problems such as pattern splicing seam, and does not cause problems such as mold scratching, and the embodiment of the present application avoids manual replacement of the grating in the subsequent processing process, simplifies the subsequent operation, and saves time.

[0067] Meanwhile, in the embodiment, the mold processing step includes:

[0068] S4. Exposure, development and transfer operations are performed on the pattern file to obtain a texture mold;

[0069] S5. Transfer and curing operations are performed on the texture mold to obtain a transfer mold.

[0070] The step S4 includes the following steps:

[0071] S41. An exposure machine receives the pattern file and performs data conversion on the gray scale value in the pattern file, divides the gray scale value into different energy levels, and then exposes the different energy levels on a glass substrate coated with photoresist;

[0072] S42. After the exposed pattern file is developed by a developing machine, the glass substrate with different texture structures is obtained, and then the transfer station transfers the glass substrate to obtain the texture mold.

[0073] The embodiment of the present application mainly adopts a gray scale exposure method to expose the pattern file, can divide the gray scale value set in the pattern file into 0-255 or 0-1023 levels of energy, and compared with the prior art, the embodiment of the present application does not need to manually replace the grating in the exposure stage, simplifies the subsequent processing procedure, reduces the labor cost, improves the yield, and improves the production rate of the mold; meanwhile, the embodiment of the present application solves the problem that the existing direct writing machine cannot arbitrarily change the unit grating structure by controlling the exposure structure of the machine through the built-in algorithm.

[0074] It should be noted that the energy level can be adjusted according to actual needs.

[0075] In the embodiment of the present application, the glass substrate after development presents different texture structures and grating angles, and different optical pattern effects are reflected or diffracted by the grating structure, thereby presenting diversified texture visual effects, wherein, Figure 6 It is a simple schematic diagram of the microstructure after exposure and development of the embodiment of the present application.

[0076] The transferring operation in the embodiment of the present application is as follows: the glass substrate is placed on the transferring table, a PET film (also referred to as a polyester substrate) is placed on the glass substrate, and UV glue (main component: polyurethane acrylate) is uniformly coated between the glass substrate and the PET film by a silica gel roller with a set speed and pressure; a UV curing lamp is turned on to irradiate from above the PET film, so that the UV glue is polymerized and cured; the UV glue and the glass substrate are separated, the PET film is transferred with the texture structure, and the texture mold is obtained.

[0077] In the step S42, the texture structure includes a planar texture structure, a 3D texture structure, and a texture structure combining planar and 3D. Figure 7 The three texture structure splicing diagrams are simply shown.

[0078] In the embodiment of the present application, when the texture structure on the glass substrate is only the planar texture structure, pre-baking and baking operations must be performed on the glass substrate before the transferring operation.

[0079] However, when the texture structure on the glass substrate is a 3D texture structure or a texture structure combining planar and 3D, in order to prevent photoresist deformation and affect the texture structure and optical effect, pre-baking and baking operations are generally not performed.

[0080] In the step S5, the texture mold obtained in the embodiment of the present application is placed on the transferring machine table to perform the same transferring operation, and the PC board (polycarbonate board) is transferred with the texture structure by the UV glue to obtain the transferring mold.

[0081] The embodiment of the present application can batch transfer the texture mold by the transferring mold.

[0082] The method for generating a texture mold by coding a puzzle provided by the embodiment of the present application includes a file generation step and a mold processing step. The embodiment of the present application pre-encodes and combines a plurality of raster structure diagrams by coding a puzzle, not only prepares a plurality of texture structures with continuously changing angles and frequencies, but also does not need to manually replace a raster in an exposure process, solves the problems of seams in pattern splicing in traditional texture mold manufacturing, the need for manual replacement of a raster structure, and the inability to prepare a large-area texture structure with continuously changing angles and frequencies, realizes the effect of simultaneously presenting a plurality of texture structures on one mold, does not need to perform film splicing, and realizes seamless splicing. At the same time, the embodiment of the present application simplifies subsequent processing operations, saves preparation time, reduces production cost, and improves the yield.

[0083] The above embodiments are the preferred embodiments of the present application, but the embodiments of the present application are not limited to the above embodiments, and any changes, modifications, substitutions, combinations, simplifications, etc. made without departing from the spirit and principles of the present application should be equivalent replacement manners and should be included in the protection scope of the present application.

Claims

1. A method for generating a texture mold by coding puzzle, comprising a file generation step and a mold processing step, characterized in that the file generation step comprises: S1. Drawing a gray scale unit graph and a gray scale path graph; S2. Changing the gray scale unit graph according to design requirements to obtain a plurality of grating structure graphs; S3. Identifying each pixel value in the gray scale path graph with the grating structure graph to generate a file by coding puzzle; Step S2 is specifically: changing the gray scale pixels of the gray scale unit graph according to the specific texture effect requirement to obtain a plurality of digital grating structure graphs containing different line numbers and high gray scale topography; Step S3 comprises the following steps: S31. The grating structure graph identifies each pixel value in the gray scale path graph; S32. Determine whether the pixel value is 0, if yes, fill the gray scale path graph; if not, first rotate and cover the grating structure, and then fill the gray scale path graph; S33. Generate a file containing a plurality of grating structures and a plurality of rotation angles by coding puzzle. The gray scale unit graph and the gray scale path graph containing gray scale pixels are drawn by software with gray scale attributes; 2. A method of creating a texture mold by encoding a puzzle as claimed in claim 1, characterized in that: The color mode of the gray scale unit graph is gray scale mode; the color mode of the gray scale path graph is gray scale mode or RGB mode. The grating structure in the grating structure graph includes planar grating structure and 3D grating structure; the planar and 3D grating structure both include slit grating structure and blazed grating structure.

3. A method of creating a texture mold by encoding a puzzle as recited in claim 1, wherein: The gray scale path graph contains different pixel values; 4. A method of creating a texture mold by encoding a puzzle as recited in claim 1, wherein: The pixel value should include the following two attributes: (a) Specify the grating structure to be used; (b) Specify the rotation angle of the grating structure, which is 0-360°. The mold processing step comprises:

5. A method of creating a texture mold by encoding a puzzle as recited in claim 1, wherein, S4. Exposure, development and transfer operation of the file to obtain a texture mold; S5. Transfer and curing operation of the texture mold to obtain a transfer mold. The step S4 comprises the following steps:

6. A method of creating a texture mold by encoding a puzzle as claimed in claim 5, characterized in that, S41. The exposure machine receives the file and converts the gray scale value in the file into different energy levels, and then exposes the different energy levels on a glass substrate coated with photoresist; S42. After the exposed file is developed by the developing machine, the glass substrate with different texture structures is obtained, and then the transfer station transfers the glass substrate to obtain the texture mold. In the step S42, the texture structure includes planar texture structure, 3D stereoscopic texture structure, and planar and 3D combined texture structure.

7. A method of creating a texture mold by encoding a puzzle as claimed in claim 6, characterized in that: When the texture structure on the glass substrate is only the planar texture structure, the glass substrate must be pre-baked and cured before the transfer operation.

8. A method of creating a texture mold by encoding a puzzle as claimed in claim 7, characterized by: ​

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