Roller sub-mold manufacturing method

Abstract

The invention discloses a method for manufacturing a roller sub-mold, which comprises the following steps of: providing a roller female mold which is in a circular tube shape and is provided with a reprinting inner surface, and surrounding the reprinting inner surface to form a long sputtering coating space; oxygen plasma is introduced into the long sputtering space in a plasma sputtering mode, so that a plasma type inner oxide layer in a circular tube shape is formed on the reprinting inner surface; a metal roller is arranged in the plasma type inner oxidation layer, a nickel transfer printing layer is formed on the outer surface of the metal roller in an electroplating mode, the plasma type inner oxidation layer is fully distributed with the nickel transfer printing layer in a gapless mode, and the metal roller and the nickel transfer printing layer jointly form a roller submodule; and separating the roller sub-mold from the roller female mold and the plasma type inner oxide layer on the roller female mold. Therefore, according to the manufacturing method of the roller sub-module, the plasma type inner oxide layer formed in the axial sputtering step is used for replacing a strong oxidant containing existing potassium dichromate, so that the safety of operators is effectively improved.

Description

Technical Field

[0001] The invention relates to a mold manufacturing method, in particular to a roller sub-mold manufacturing method. Background Art

[0002] The existing roller type mold manufacturing method often uses a strong oxidant containing potassium dichromate (K2Cr2O7) in the mold forming process, but the potassium dichromate is actually a highly carcinogenic substance, which is not conducive to the safety of the operators. Therefore, the inventors believe that the above defects can be improved, and have devoted themselves to research and combined with the application of scientific principles, and finally proposed a reasonable design and effective improvement of the present invention. Summary of the invention

[0003] The embodiment of the present invention provides a method for manufacturing a roller sub-mold, which can effectively improve the defects that may occur in the existing roller-type mold manufacturing method.

[0004] The embodiment of the present invention discloses a method for manufacturing a roller sub-mold, which includes: a preparation step: providing a roller mother mold, which is in a cylindrical shape and has a reprinted inner surface; wherein the reprinted inner surface of the roller mother mold surrounds a long sputtering space; an axial sputtering step: introducing oxygen plasma into the long sputtering space of the roller mother mold by plasma sputtering to form a plasma-type inner oxide layer on the reprinted inner surface; wherein the plasma-type inner oxide layer covers the reprinted inner surface and is in a cylindrical shape to surround a reprinted space; a sub-mold forming step: placing a metal roller in the reprinted space, and electroplating the outer surface of the metal roller to form a nickel transfer layer, which is completely covered with the plasma-type inner oxide layer; wherein the metal roller and the nickel transfer layer together constitute a roller sub-mold; and a separation step: separating the roller sub-mold from the roller mother mold and the plasma-type inner oxide layer thereon.

[0005] Preferably, in the axial sputtering step, the roller master mold rotates at a constant speed around a rotation axis, so that the plasma-type inner oxide layer formed by oxygen plasma has a thickness of 0.1 micrometers (μm) to 9 micrometers.

[0006] Preferably, in the sub-mold forming step, the center line of the metal roller and the center line of the imprinting space overlap at the rotation axis, so that the metal roller and the plasma-type inner oxide layer are spaced apart.

[0007] Preferably, the length of the metal roller is 0.8 meters to 1.6 meters and is further defined as a copper metal roller or a chrome metal roller.

[0008] Preferably, in the preparation step, the production process of the roller master mold includes: providing a front roller, which includes a cylinder and a photoresist layer formed on the outer surface of the cylinder; forming a sputtered nickel layer on the photoresist layer facing the front roller, and making the sputtered nickel layer cover the photoresist layer and form a cylindrical shape; electroplating to form an electroplated nickel layer on the sputtered nickel layer formed on the front roller; wherein the sputtered nickel layer and the electroplated nickel layer together constitute the roller master mold; and separating the roller master mold from the photoresist layer of the front roller.

[0009] Preferably, in the production process of the roller master mold in the preparation step, the electroplated nickel layer covers the sputtered nickel layer without any gap.

[0010] Preferably, the roller mold manufacturing method further includes a pre-step before the preparation step: providing a master mold sputtering device, which includes: a vacuum sputtering chamber; a rotating mechanism, which is installed in the vacuum sputtering chamber and defines a rotation axis; wherein the rotating mechanism is provided for the roller master mold to be set in the preparation step, and the roller master mold is rotated around the rotation axis in the axial sputtering step; and two axial plasma sputtering mechanisms, which are adjacent to the rotating mechanism and located at the rotation axis; wherein the two axial plasma sputtering mechanisms introduce oxygen plasma along the axial direction of the roller master mold and toward the elongated sputtering space in the axial sputtering step to form a plasma-type inner oxide layer.

[0011] Preferably, the preceding step further provides an electroplating device located downstream of the two axial plasma sputtering mechanisms; wherein, during the sub-mold forming step, the electroplating device electroplates a nickel transfer layer on the outer surface of the metal roller.

[0012] Preferably, the preceding step further provides a plate disassembly device, which is located downstream of the electroplating device; wherein the plate disassembly device separates the roller sub-mold from the roller mother mold and the plasma-type inner oxide layer thereon during the separation step.

[0013] Preferably, the two axial plasma sputtering mechanisms are located within a region of the elongated sputtering space extending toward opposite sides along the rotation axis, and the two axial plasma sputtering mechanisms are spaced apart from each other at a distance of no more than 1.7 meters on the rotation axis.

[0014] In summary, the roller mold manufacturing method disclosed in the embodiment of the present invention uses the plasma-type inner oxide layer formed by the axial sputtering step to replace the existing strong oxidant containing potassium dichromate, thereby effectively improving the safety of operators.

[0015] To further understand the features and technical contents of the present invention, please refer to the following detailed description and drawings of the present invention. However, these descriptions and drawings are only used to illustrate the present invention and are not intended to limit the protection scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the roller sub-mold production equipment of the first embodiment of the present invention.

[0017] Figure 2 Schematic diagram of the preparatory steps of the roller sub-mold manufacturing method according to the first embodiment of the present invention.

[0018] Figure 3 Schematic diagram of the preparation steps and axial sputtering steps of the roller sub-mold manufacturing method according to the first embodiment of the present invention.

[0019] Figure 4 Schematic diagram of the sub-mold forming steps of the roller sub-mold manufacturing method according to the first embodiment of the present invention.

[0020] Figure 5 Schematic diagram of the sub-mold forming steps of the roller sub-mold manufacturing method according to the first embodiment of the present invention.

[0021] Figure 6 Schematic diagram of the separation steps of the roller sub-mold manufacturing method according to the first embodiment of the present invention.

[0022] Figures 7 to 10 It is a schematic diagram of the production process of a roller master mold in the preparation step of the roller sub-mold manufacturing method of the second embodiment of the present invention. DETAILED DESCRIPTION

[0023] The following is an explanation of the implementation method of the "roller sub-mold manufacturing method" disclosed in the present invention through specific specific embodiments. Those skilled in the art can understand the advantages and effects of the present invention from the contents disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and the details in this specification can also be modified and changed in various ways based on different viewpoints and applications without departing from the concept of the present invention. In addition, it should be noted in advance that the drawings of the present invention are only simple schematic illustrations and are not depicted according to actual dimensions. The following implementation methods will further explain the relevant technical contents of the present invention in detail, but the disclosed contents are not intended to limit the scope of protection of the present invention.

[0024] It should be understood that, although the terms "first", "second", "third", etc. may be used herein to describe various components or signals, these components or signals should not be limited by these terms. These terms are mainly used to distinguish one component from another component, or one signal from another signal. In addition, the term "or" used herein may include any one or more combinations of the associated listed items depending on the actual situation.

[0025] [Example 1]

[0026] See also Figures 1 to 6, which is the first embodiment of the present invention. This embodiment discloses a method for manufacturing a roller sub-mold, which sequentially includes (or implements) a pre-step S110, a preparation step S120, an axial sputtering step S130, a sub-mold forming step S140, and a separation step S150. The specific implementation of the above-mentioned multiple steps will be described in sequence below, but they can also be adjusted and changed according to design requirements and are not limited to this embodiment.

[0027] The preceding step S110: Figures 1 to 3 As shown, a roller mold production device 100 is provided, which includes a mother mold sputtering device 1, an electroplating device 2 arranged downstream of the mother mold sputtering device 1, and a plate disassembling device 3 arranged downstream of the electroplating device 2. The processing objects between the mother mold sputtering device 1, the electroplating device 2, and the plate disassembling device 3 can be carried out by various suitable transfer methods and mechanisms, which are not limited here.

[0028] The master mold sputtering device 1 includes a vacuum sputtering chamber 11, a rotating mechanism 12 installed in the vacuum sputtering chamber 11, and two axial plasma sputtering mechanisms 13 adjacent to the rotating mechanism 12. Specifically, the vacuum sputtering chamber 11 is elongated and preferably arranged in a transverse direction, and the rotating mechanism 12 is located in the vacuum sputtering chamber 11 and defines a rotation axis R. In this embodiment, the rotating mechanism 12 may include a plurality of rolling wheels and is located below the vacuum sputtering chamber 11 to carry a roller master mold 200 disposed in the vacuum sputtering chamber 11. Furthermore, the rotating mechanism 12 can be used to make the roller master mold 200 rotate (at a constant speed) with the rotation axis R as the center, and the specific structure of the rotating mechanism 12 can be adjusted and changed according to design requirements, and is not limited to this embodiment and the accompanying drawings.

[0029] The two axial plasma sputtering mechanisms 13 are adjacent to the rotating mechanism 12 and are located on the rotation axis R. In this embodiment, the two axial plasma sputtering mechanisms 13 may be separated from each other by a distance of no more than 1.7 meters (m) (or greater than the length of the roller master mold 200) on the rotation axis R, and the two axial plasma sputtering mechanisms 13 are preferably arranged in a mirror-symmetrical manner, but the present invention is not limited thereto.

[0030] It should be noted that the roller master mold 200 in this embodiment is in a cylindrical shape and has a reprinted inner surface 203, which surrounds a long sputtering space S203, and the two axial plasma sputtering mechanisms 13 are located in the region of the long sputtering space S203 extending toward opposite sides along the rotation axis R, and are used to pass oxygen plasma P along the axial direction of the roller master mold 200 and toward the long sputtering space S203. Among them, the axial direction of the roller master mold 200 in this embodiment is described as overlapping with the rotation axis R. In other words, any sputtering mechanism that does not use a plasma sputtering mechanism or is not arranged along the axial direction is different from the axial plasma sputtering mechanism 13 indicated in this embodiment.

[0031] The mother mold sputtering device 1, the electroplating device 2, and the disassembling device 3 belong to the same production line of the roller mold production equipment 100; that is, the mother mold sputtering device 1, the electroplating device 2, and the disassembling device 3 are arranged in sequence, and their functions are operated in succession to realize the roller mold manufacturing method. Among them, the electroplating device 2 is located downstream of the two axial plasma sputtering mechanisms 13, and the structures of the electroplating device 2 and the disassembling device 3 can be adjusted and changed according to design requirements, and the present invention is not limited here.

[0032] The above is an explanation of the pre-step S110 or the roller mold production equipment 100 in this embodiment, and the roller mold production equipment 100 is introduced by combining the mother mold sputtering device 1 with the electroplating device 2 and the plate disassembly device 3, but the roller mold production equipment 100 or the mother mold sputtering device 1 can also be used separately (such as: sold) or combined with other devices according to design requirements, which is not limited here.

[0033] Furthermore, if Figures 1 to 6 As shown, the roller sub-mold manufacturing method will be implemented in conjunction with the roller sub-mold production equipment 100 to implement other steps. However, in other embodiments not shown in the present invention, the preparation step S120, the axial sputtering step S130, the sub-mold forming step S140, and the separation step S150 can also be implemented by a device different from the roller sub-mold production equipment 100.

[0034] The preparation step S120: Figure 3 As shown, the roller master mold 200 is provided. The specific production process or structure of the roller master mold 200 can be adjusted and changed according to design requirements, and will not be repeated here. In other words, the rotating mechanism 12 is provided for the roller master mold 200 in the preparation step S120 of this embodiment.

[0035] The axial sputtering step S130: Figure 3 and Figure 4 As shown, the oxygen plasma P is introduced into the elongated sputtering space S203 of the roller master mold 200 by plasma sputtering to form a plasma-type inner oxide layer 300 on the imprint inner surface 203. The rotating mechanism 12 rotates the roller master mold 200 around the rotation axis R in the axial sputtering step S130 of this embodiment. Furthermore, the two axial plasma sputtering mechanisms 13 introduce the oxygen plasma P along the axial direction of the roller master mold 200 and toward the elongated sputtering space S203 in the axial sputtering step S130 of this embodiment to form the plasma-type inner oxide layer 300.

[0036] In more detail, the total amount of the oxygen plasma P introduced into the elongated sputtering space S203 by any one of the axial plasma sputtering mechanisms 13 in this embodiment is preferably 95% to 105% of the total amount of the oxygen plasma P introduced into the elongated sputtering space S203 by another one of the axial plasma sputtering mechanisms 13, thereby facilitating uniform distribution of the oxygen plasma P in the elongated sputtering space S203.

[0037] Furthermore, in the axial sputtering step S130 of the present embodiment, the roller master mold 200 preferably rotates at a constant speed (through the rotating mechanism 12) with the rotation axis R as the center, so that the plasma-type inner oxide layer 300 formed by the oxygen plasma P has better uniformity and a thickness of 0.1 microns (μm) to 9 microns.

[0038] In addition, the plasma-type inner oxide layer 300 covers the reprint inner surface 203 and is in a cylindrical shape to surround and form a reprint space S300. Furthermore, the plasma-type inner oxide layer 300 is, for example, a nickel oxide layer, but the present invention is not limited thereto.

[0039] As described above, the plasma-type inner oxide layer 300 has better uniformity due to the axial sputtering step S130, so that the surface defining the reprint space S300 can more accurately form an appearance corresponding to the reprint inner surface 203. Furthermore, the roller mold manufacturing method uses the plasma-type inner oxide layer 300 formed by the axial sputtering step S130 to replace the existing strong oxidant containing potassium dichromate, thereby effectively improving the safety of the operator.

[0040] The sub-mold forming step S140: Figure 4 and Figure 5As shown, a metal roller 41 is placed in the reprinting space S300 (e.g., the center line of the metal roller 41 overlaps with the center line of the reprinting space S300 at the rotation axis R, so that the metal roller 41 and the plasma-type inner oxide layer 300 are spaced apart), and a nickel transfer layer 42 is electroplated on the outer surface of the metal roller 41, which covers the plasma-type inner oxide layer 300 without gaps.

[0041] In this embodiment, when the plasma-type inner oxide layer 300 (in the sub-mold forming step S140) is provided for the metal roller 41 to be placed therein, the electroplating device 2 electroplates the nickel transfer layer 42 on the outer surface of the metal roller 41. The nickel transfer layer 42 is formed to have an appearance corresponding to (e.g., complementary to) the reprinted inner surface 203 by covering the plasma-type inner oxide layer 300 without any gaps.

[0042] In addition, the length of the metal roller 41 can be 0.8 meters to 1.6 meters and is further limited to a copper metal roller or a chrome metal roller, but not limited thereto. Furthermore, the metal roller 41 and the nickel transfer layer 42 together form a roller sub-mold 4.

[0043] The separation step S150: Figure 6 As shown, the roller mold 4 is separated from the roller master mold 200 and the plasma-type inner oxide layer 300 thereon. Specifically, the demolding device 3 separates the roller mold 4 from the roller master mold 200 and the plasma-type inner oxide layer 300 thereon in the separation step S150 of this embodiment.

[0044] Furthermore, the specific separation mechanism adopted by the disassembling device 3 can be adjusted and changed according to the design requirements, as illustrated below, but not limited to. The disassembling device 3 can firstly use a suction cup to create a small gap between the roller sub-mold 4 and the plasma-type inner oxide layer 300, and then input a strong airflow toward the gap to separate the roller sub-mold 4 and the plasma-type inner oxide layer 300 along the interface between them. Alternatively, the disassembling device 3 can also separate the roller mother mold 200 and the plasma-type inner oxide layer 300 thereon from the roller sub-mold 4 in a sheet-like manner (e.g., peeling).

[0045] [Example 2]

[0046] See also Figures 7 to 10 As shown, this is the second embodiment of the present invention. Since this embodiment is similar to the above-mentioned first embodiment, the similarities between the two embodiments will not be described in detail, and the differences between this embodiment and the above-mentioned first embodiment are roughly described as follows:

[0047] In the preparation step S120 of the present embodiment, the production process of the roller master mold 200 is as follows: providing a front roller 400, which includes a cylinder 401 and a photoresist layer 402 formed on the outer surface of the cylinder 401; forming a sputtered nickel layer 201 facing the front roller 400 and on the photoresist layer 402, and making the sputtered nickel layer 201 cover the photoresist layer 402 and form a cylindrical shape; electroplating to form an electroplated nickel layer 202 on the sputtered nickel layer 201 formed on the front roller 400, which covers the sputtered nickel layer 201 without gaps, and the sputtered nickel layer 201 and the electroplated nickel layer 202 together constitute the roller master mold 200; and separating the roller master mold 200 from the photoresist layer 402 of the front roller 400. It should be additionally explained that the related components, devices, or equipment used in the production process of the roller master mold 200 can be changed according to design requirements and will not be elaborated here.

[0048] [Technical Effects of Embodiments of the Invention]

[0049] In summary, the roller mold manufacturing method disclosed in the embodiment of the present invention uses the plasma-type inner oxide layer formed by the axial sputtering step to replace the strong oxidant containing potassium dichromate, thereby effectively improving the safety of the operator. Furthermore, the plasma-type inner oxide layer has good uniformity due to the axial sputtering step, so that the surface defining the reprint space can more accurately form an appearance corresponding to the reprint inner surface.

[0050] Furthermore, the roller sub-mold production equipment and master mold sputtering device disclosed in the embodiments of the present invention adopt two axial plasma sputtering mechanisms to facilitate the application of oxygen plasma to the roller master mold, thereby providing a roller-type mold production mechanism that is different from the previous one, thereby expanding the development direction of the roller-type mold.

[0051] The contents disclosed above are only preferred feasible embodiments of the present invention, and are not intended to limit the patent scope of the present invention. Therefore, all equivalent technical changes made using the contents of the present invention description and drawings are included in the patent scope of the present invention.

Claims

1. A method for manufacturing a roller mold, characterized in that: The roller sub-mold manufacturing method comprises: A preparation step: providing a roller master mold, the roller master mold is in a cylindrical shape and has a reprinted inner surface; wherein the reprinted inner surface of the roller master mold surrounds and forms a long sputtering space; An axial sputtering step: introducing oxygen plasma into the elongated sputtering space of the roller master mold by plasma sputtering to form a plasma-type inner oxide layer on the inner surface of the reprint; wherein the plasma-type inner oxide layer covers the inner surface of the reprint and is in a cylindrical shape to surround a reprint space; a sub-mold forming step: placing a metal roller in the reprinting space, and electroplating a nickel transfer layer on the outer surface of the metal roller, wherein the nickel transfer layer is completely covered with the plasma-type inner oxide layer; wherein the metal roller and the nickel transfer layer together constitute a roller sub-mold; and A separation step is to separate the roller sub-mold from the roller master mold and the plasma-type inner oxide layer on the roller master mold.

2. The method for manufacturing a roller sub-mold according to claim 1, characterized in that: In the axial sputtering step, the roller master mold rotates at a constant speed around a rotation axis, so that the plasma-type inner oxide layer formed by the oxygen plasma has a thickness of 0.1 micrometers to 9 micrometers.

3. The method for manufacturing a roller sub-mold according to claim 2, characterized in that: In the sub-mold forming step, the center line of the metal roller and the center line of the reprinting space overlap on the rotation axis, so that the metal roller and the plasma-type inner oxide layer are spaced apart.

4. The method for manufacturing a roller sub-mold according to claim 1, characterized in that: The length of the metal roller is 0.8 meters to 1.6 meters and is defined as a copper metal roller or a chrome metal roller.

5. The method for manufacturing a roller sub-mold according to claim 1, characterized in that: In the preparation step, the production process of the roller master mold includes: A front roller is provided, the front roller comprising a cylinder and a photoresist layer formed on the outer surface of the cylinder; A sputtered nickel layer is formed on the photoresist layer toward the front roller, and the sputtered nickel layer covers the photoresist layer to form a circular tube shape; forming an electroplated nickel layer by electroplating on the sputtered nickel layer formed on the front roller; wherein the sputtered nickel layer and the electroplated nickel layer together constitute the roller master mold; and The roller master mold is separated from the photoresist layer of the front roller.

6. The method for manufacturing a roller sub-mold according to claim 5, characterized in that: In the production process of the roller master mold in the preparation step, the electroplated nickel layer covers the sputtered nickel layer without any gap.

7. The method for manufacturing a roller sub-mold according to claim 1, characterized in that: The roller sub-mold manufacturing method further comprises a pre-step before the preparation step: providing a mother mold sputtering device, the mother mold sputtering device comprising: a vacuum sputtering chamber; a rotating mechanism installed in the vacuum sputtering chamber and defining a rotation axis; wherein the rotating mechanism is used to place the roller master mold in the preparation step, and rotates the roller master mold around the rotation axis in the axial sputtering step; and Two axial plasma sputtering mechanisms are adjacent to the rotating mechanism and located at the rotation axis; wherein, during the axial sputtering step, the two axial plasma sputtering mechanisms introduce the oxygen plasma along the axial direction of the roller master mold and toward the elongated sputtering space to form the plasma-type inner oxide layer.

8. The method for manufacturing a roller sub-mold according to claim 7, characterized in that: The preceding step also provides an electroplating device, which is located downstream of the two axial plasma sputtering mechanisms; wherein, during the sub-mold forming step, the electroplating device electroplates the outer surface of the metal roller to form the nickel transfer layer.

9. The method for manufacturing a roller sub-mold according to claim 8, characterized in that: The preceding step also provides a plate disassembly device, which is located downstream of the electroplating device; wherein the plate disassembly device separates the roller sub-mold from the roller master mold and the plasma-type inner oxide layer on the roller master mold during the separation step.

10. The method for manufacturing a roller sub-mold according to claim 7, characterized in that: The two axial plasma sputtering mechanisms are located within a region of the elongated sputtering space extending toward opposite sides along the rotation axis, and the two axial plasma sputtering mechanisms are spaced apart from each other at a distance of no more than 1.7 meters on the rotation axis.

Images