Seamless combination mechanism for total prism mold

Abstract

The utility model discloses a full prism mould seamless combination mechanism which comprises a table top and fastening tools, the fastening tools are symmetrically arranged on the table top, template areas are arranged in the fastening tools, a combination area is arranged between the fastening tools, the table top is provided with an observation window, and the observation window is matched with the combination area. By means of the design, the seamless combined die for the thin plates is achieved, the production cycle is short, and meanwhile the quality is high. According to the utility model, thin plate combination is adopted, and copying and processing periods are shortened. And meanwhile, the influence of machining stress can be avoided, the quality is guaranteed, and the market period of products is shortened.

Description

Technical Field

[0001] The utility model relates to the technical field of prisms, in particular to a seamless assembly mechanism of a full prism mold. Background Art

[0002] Currently, the requirements for engraving full-prismatic templates are relatively high. The micro-prism engraving process has a long cycle and extremely stringent requirements on the engraving environment and tools. Tool wear and tear affect the processing accuracy. If the tool is changed or the machine is stopped midway, the position will be slightly offset during operation, and it will not be able to completely match the previous tool path. Therefore, in the actual processing process, the area of ​​the prism matrix cannot reach a relatively large specification, and the area of ​​the mold can only be increased through combination. In the process of increasing the area, it is usually necessary to make a thicker template, smooth the back surface, and then combine it.

[0003] However, using thick templates for production requires a long production cycle, making it difficult to keep up with market changes. Improper electroforming stress adjustment can cause premature separation and damage the original mold. Furthermore, subsequent processing steps such as cutting, trimming, and fine grinding of thick plates can still generate processing stress. This stress concentration can cause cracks between the substrate and the replica workpiece, allowing liquid to be absorbed, damaging both the original mold and the replica.

[0004] While using thin plates for assembly shortens production cycles and facilitates processing, the thin plates can bend after being separated from the original mold due to stress or other issues during operation and processing, resulting in curved prism surfaces. During assembly, the two cannot achieve consistency, resulting in transition discrepancies and a lack of integrity.

[0005] Therefore, it is necessary to make improvements to the above problems. Summary of the Invention

[0006] The utility model aims at the defects of the prior art such as long production cycle and poor mold quality, and provides a new seamless combination mechanism of full prism mold.

[0007] In order to solve the above technical problems, the present invention is implemented through the following technical solutions:

[0008] A seamless assembly mechanism for a full prism mold includes a table and a fastening tooling, wherein the fastening tooling is symmetrically arranged on the table, a template area is arranged inside the fastening tooling, a combination area is arranged between the fastening toolings, and an observation window is provided on the table, which cooperates with the combination area.

[0009] The formwork area is used to place the formwork to be assembled, and the fastening fixture is used to fasten the assembled formwork. The assembled formwork is made of thin plates. The assembly area is used to assemble two forms. An observation window allows for observation of the assembled formwork to ensure accurate alignment and welding. The combination of the table and fastening fixture ensures the stability of the assembled formwork during processing. The fastening fixtures are symmetrically positioned on the table, providing uniform support and clamping force, ensuring precise alignment of the assembled formwork during assembly.

[0010] Through the above design, the utility model realizes a thin plate seamless combination mold with a short production cycle and high quality. The utility model uses a thin plate combination to shorten the duplication and processing cycle. It protects the original mold and avoids the influence of processing stress, thus ensuring quality and shortening the product's time to market.

[0011] Preferably, in the seamless assembly mechanism of the full prism mold described above, the fastening fixture includes upper and lower parallel reference blocks, and a template area is formed between the reference blocks.

[0012] The datum blocks ensure accurate positioning of the template within the fixture, improving consistency and repeatability of template placement. The parallel placement of the datum blocks simplifies the template installation process, allowing for quick and easy placement within the fixture. The parallel structure of the datum blocks provides uniform support, enhancing the overall stability and durability of the fixture. The datum block design helps evenly distribute stress during processing, reducing template deformation caused by stress concentration.

[0013] Preferably, in the seamless assembly mechanism of the full prism mold described above, tightening threaded holes are symmetrically provided on both sides of the reference block, and the reference blocks are threadedly connected.

[0014] Threaded connections provide a stable and adjustable connection, enhancing the structural stability of the clamping fixture when clamping the formwork. Threaded connections allow precise adjustment of the distance between the reference blocks to accommodate varying formwork thicknesses, ensuring formwork flatness and precise assembly. Threaded connections ensure uniform clamping of the reference blocks, ensuring the formwork remains parallel during machining. Compared to other connection methods, threaded connections offer greater durability and reliability, making them suitable for long-term and repeated use. Threaded connections also allow for adjustable pressure to accommodate varying formwork materials and thicknesses.

[0015] Preferably, in the seamless combination mechanism of the full prism mold described above, the table top is a magnetic table top, and the fastening tool is magnetically connected to the table top.

[0016] The magnetic connection allows the fastening tool to be quickly and easily positioned and fixed to the table, improving work efficiency and simplifying the installation and adjustment process of the fastening tool, making operation easier. The magnetic connection also facilitates the position adjustment of the fastening tool, facilitating the close alignment of the template.

[0017] Preferably, in the above-mentioned seamless combination structure of a full prism mold, the template areas extend into the combination area in opposite directions.

[0018] The design of the template areas extending into the assembly area in opposite directions helps to ensure the precise docking of the templates during assembly, improves the assembly accuracy of the entire mold, and is also beneficial for the grinding of the templates before assembly.

[0019] A method for seamlessly assembling a full prism mold, comprising any one of the seamless assembly mechanisms described above, further comprising the following steps:

[0020] S1: Make the template, and add at least 10cm of margin area around the original mold during production;

[0021] S2: Cut the cutting area and the combination edge position of the template to obtain the template to be combined;

[0022] S3: Use fastening tools to clamp and flatten the template to be assembled;

[0023] S4: fine grinding the combined edge of the combined template;

[0024] S5: Bring the fastening fixtures closer, align the combined edges of the two templates to be combined, and use laser to perform seam welding on the back to obtain a seamless mold.

[0025] Step S1 is used to make a template. Adding a margin area helps to ensure the uniformity of the thickness of the effective area in the center of the template after replication. The electroforming deposition rate around the template is higher than that in the middle area. Increasing the margin area can avoid inconsistent thickness caused by edge effects. In addition, the thickness of each template made by the original mold of the utility model can be inconsistent. When assembling, the front side can be leveled based on the front side, which reduces the difficulty of production. Step S2 is used to cut the cutting area and the combination edge position. Pre-cutting can reduce the subsequent finishing work required, shorten the processing time, and improve the overall processing efficiency. Pre-cutting is a rough processing, which can roughly trim the template into place and shorten the time for subsequent fine grinding. Step S3 is used to clamp and flatten the template to be combined. Flatten the template as much as possible to ensure that the subsequent combination edge is perpendicular to the prism surface after processing. Tighten the tooling to clamp the template to ensure that the template remains flat during subsequent processing and assembly to avoid errors caused by bending or warping of the template. By clamping and flattening operations, the precise alignment of the template edges is ensured, which helps to reduce the stress caused by uneven force during the processing and assembly of the template, and reduces the risk of cracking and deformation. The template to be assembled is clamped with a fastening fixture because the template thickness is thin during the template replication process, and the force during the separation process will slightly bend, causing the prism matrix to be not in the same plane. After clamping with a fastening fixture, the template can be leveled, and the combined edge ground in the subsequent grinding process will be perpendicular to the prism surface, which can ensure the tightness of the seam in the subsequent assembly process. Step S4 is used to fine-grind the prism of the combined edge, and step S5 is used for laser welding to achieve a tight and seamless combination.

[0026] Preferably, in the above-described method for seamlessly assembling a full prism mold, a reference steel plate is used to increase a margin area in step S1, a window is opened on the reference steel plate, and the original mold is embedded therein, and the thickness of the produced template is 0.4 mm to 3 mm.

[0027] The use of a reference steel plate ensures uniform thickness in the effective center area of ​​the replicated template, simplifies the fixing and positioning of the original template, and improves processing efficiency. The template is made of thin plate, which shortens the production cycle and is easy to process.

[0028] Preferably, in the above-mentioned method for seamlessly assembling a full prism mold, step S2 is first measured with a microscope, and then a wire cutting device is used to cut according to the cutting area and the combination edge position.

[0029] The use of a microscope allows for precise measurement of the cutting position before cutting, ensuring cutting accuracy. Accurate measurement allows the wire EDM to cut along the precise predetermined path, improving processing quality. The trimmed area serves as a non-combined edge for later processing, facilitating pick-up and welding reinforcement.

[0030] Preferably, in the above-described method for seamlessly assembling a full prism mold, when the template to be assembled is clamped in step S3, the assembly edges of the template to be assembled extend out of the fastening tooling by 0.5 mm to 1.1 mm.

[0031] Extending the template facilitates observation and helps improve the alignment accuracy of the template during assembly, ensuring welding quality. Less extension helps keep the template flat and prevents it from bending under gravity, thus ensuring assembly quality.

[0032] Preferably, in the above-described method for seamlessly assembling a full prism mold, step S4 is to first observe with a microscope, and then finely grind with a precision grinder to remove the grooves so that the assembled edge has a complete prism when observed under a microscope.

[0033] Through microscopic observation and precision grinding, the grooves are trimmed to ensure the integrity of the prisms at the combined edges, avoid edge defects, and maintain the integrity of the prism's reflective surface. By trimming the grooves and leaving the prism intact, when the templates are assembled, the weld seam at the combined edge will appear consistent with the original prism grooves, achieving a seamless assembly. Secondly, because the prism's reflective surface is beveled, if the grinding position is on the prism, the width of the two sides will be slightly inconsistent, resulting in uneven assembly positions. Furthermore, if the grinding reaches the prism surface, the grinding process will also damage the prism's reflective surface.

[0034] Preferably, the above-described method for seamlessly combining a full prism mold, step S5, first place the fastening tooling on the table, then observe it under a microscope, move the fastening tooling closer, align the combination edges of the two templates to be combined, so that the combination edges are located at the observation window, and finally use a laser to perform seam welding on the back, and then seam welding the cut area of ​​the front combination edge to obtain a seamless mold.

[0035] This design ensures the prism grooves are aligned. Precise alignment and seamless welding ensure the mold's structural integrity and quality. Seamless welding reduces optical distortion and improves the optical performance of the prism mold. Additional welding on the trimmed area of ​​the front panel further strengthens the panel's connection.

[0036] Preferably, in the above-described method for seamlessly assembling a full prism mold, when the template to be assembled is clamped in step S3, a PET protective film is placed between the fastening tooling and the template to be assembled.

[0037] The PET protective film prevents direct contact between the fastening fixture and the template prism, thereby preventing scratches or wear on the template surface during the clamping process, helping to protect the optical surface and reducing marks left by the fastening fixture on the template. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a structural diagram of the utility model;

[0039] Figure 2 This is a schematic diagram of the top structure of the utility model;

[0040] Figure 3 It is a schematic diagram of the local structure of the utility model;

[0041] Figure 4 It is a structural diagram of the template in the utility model;

[0042] Figure 5 This is a schematic structural diagram of the prism area of ​​the template in the present invention under microscope observation. DETAILED DESCRIPTION

[0043] The following is combined with Figure 1-5 The present invention is further described in detail with reference to the following specific embodiments, but they are not intended to limit the present invention:

[0044] Example 1

[0045] A seamless assembly mechanism for a full prism mold includes a table top 1 and a fastening tool 2. The fastening tool 2 is symmetrically arranged on the table top 1. A template area 3 is provided inside the fastening tool 2. A combination area 4 is provided between the fastening tool 2. The table top 1 is provided with an observation window 5, and the observation window 5 cooperates with the combination area 4.

[0046] Preferably, the fastening tool 2 includes reference blocks 6 arranged in parallel up and down, and a template area 3 is formed between the reference blocks 6.

[0047] Preferably, tightening threaded holes 7 are symmetrically provided on both sides of the reference block 6 , and the reference blocks 6 are threadedly connected.

[0048] Preferably, the table top 1 is a magnetic table top, and the fastening tool 2 is magnetically connected to the table top 1 .

[0049] Preferably, the template region 3 extends into the combination region 4 in opposite directions.

[0050] A method for seamlessly assembling a full prism mold, comprising any one of the seamless assembly mechanisms described above, further comprising the following steps:

[0051] S1: Make the template, and add at least 10cm of margin area around the original mold during production;

[0052] S2: Cut the cutting area and the combination edge position of the template to obtain the template to be combined;

[0053] S3: Use the fastening tool 2 to clamp and flatten the template to be assembled;

[0054] S4: fine grinding the combined edge of the combined template;

[0055] S5: Bring the fastening tooling 2 closer, align the combined edges of the two templates to be combined, and use laser to perform seam welding on the back to obtain a seamless mold.

[0056] Preferably, in step S1, a reference steel plate is used to increase a margin area, a window is opened on the reference steel plate, and the original mold is embedded therein, and the thickness of the produced template is 0.4 mm to 3 mm.

[0057] Preferably, in step S2, a microscope is used for measurement, and then a wire cutting device is used to cut according to the cutting area and the combined edge position.

[0058] Preferably, when the template to be assembled is clamped in step S3, the assembled edge of the template to be assembled extends out of the fastening tooling 2 by 0.5 mm to 1.1 mm.

[0059] Preferably, in step S4, the prism is first observed under a microscope and then finely ground with a precision grinder to remove the grooves so that the combined edge has a complete prism when observed under a microscope.

[0060] Preferably, in step S5, the fastening tool 2 is first placed on the table 1, and then observed under a microscope, the fastening tool 2 is moved closer, and the combined edges of the two templates to be combined are aligned so that the combined edges are located at the observation window 5. Finally, a laser is used to perform seam welding on the back, and then the cut area of ​​the combined edge on the front is seam welded to obtain a seamless mold.

[0061] Preferably, when the template to be assembled is clamped in step S3, a PET protective film is placed between the fastening tool 2 and the template to be assembled.

[0062] The thickness of the template is 0.4mm to 3mm, which can be 0.4mm, 1.7mm, or 3mm. The thickness of the thick template on the market is generally above 7mm.

[0063] Add at least 10cm of margin area around the original mold. The larger the margin, the better the effect. For cost considerations, it can generally be 10cm, 15cm, 20cm, or 25cm.

[0064] The combined edge of the template to be combined extends out of the fastening tool 2 by 0.5mm to 1.1mm, which can be 0.5mm, 0.8mm, 1mm, or 1.1mm.

[0065] like Figure 4As shown, step S1 produces a template 100. Template 100 includes a prism area 101, a margin area 102, and a cutting area 103. The upper and lower sides of the prism area 101 and the cutting area 103 are combined edges 104. Multiple templates 100 are combined by aligning the combined edges 104 in sequence. The length and width of the prism area 101 are generally between 30 mm and 80 mm, and can be 30 mm, 55 mm, or 80 mm. The width of the cutting area 103 is generally between 4 mm and 6 mm, and can be 4 mm, 5 mm, or 6 mm.

[0066] In step S2, the prism area 101 and the cutting area 103 are cut, and the residual area 102 is cut off, leaving the prism area 101 and the cutting area 103, to obtain the template to be assembled. The cutting area 103 is used for later processing to facilitate picking. Avoid damaging the prism area 101.

[0067] In step S5, the back edges 104 of the two templates to be assembled are welded first, and then the front edges 104 corresponding to the cutout areas 103 are reinforced by welding. This can strengthen the weld connection between the two templates to be assembled and avoid damaging the prism area 101.

[0068] like Figure 5 As shown, there are black grooves between the upper and lower rows of white prisms in prism area 101. The grooves are typically 10 to 20 μm in diameter. In step S4, the black grooves at the combined edge 104 are removed, leaving only the intact white prisms. In step S5, after the two templates are assembled, the weld at the combined edge 104 will be visually consistent with the original prism grooves, achieving a seamless assembly.

[0069] In short, the above description is only a preferred embodiment of the present invention, and all equivalent changes and modifications made within the scope of the patent application for the present invention should fall within the scope of the present invention.

Claims

1. A seamless assembly mechanism for a full prism mold, characterized by: The invention comprises a table (1) and a fastening tool (2), wherein the fastening tool (2) is symmetrically arranged on the table (1), a template area (3) is arranged inside the fastening tool (2), a combination area (4) is arranged between the fastening tool (2), and the table (1) is provided with an observation window (5), and the observation window (5) cooperates with the combination area (4).

2. The seamless assembly mechanism of a full prism mold according to claim 1, characterized in that: The fastening tool (2) comprises upper and lower reference blocks (6) arranged in parallel, with a template area (3) formed between the reference blocks (6).

3. The seamless assembly mechanism of a full prism mold according to claim 2, characterized in that: Tightening threaded holes (7) are symmetrically provided on both sides of the reference block (6), and the reference blocks (6) are threadedly connected.

4. The seamless assembly mechanism of a full prism mold according to claim 1, characterized in that: The table top (1) is a magnetic table top, and the fastening tool (2) is magnetically connected to the table top (1).

5. The seamless assembly mechanism of a full prism mold according to claim 1, characterized in that: The template areas (3) extend toward each other into the combination area (4).

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