Device and method for injection molding

Abstract

To provide a device and a method for enhancing manufacturing accuracy of a manufactured injection molding product.SOLUTION: The present invention relates, in particular to an injection molding device, in particular to micro-injection molding device, at least comprising a mold with a first mold half and a second mold half, wherein the first mold half and the second mold half define an injection molding space in a closed state of the mold, and an insert arranged in the injection molding space.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for injection molding and an apparatus for injection molding. Injection molding as a manufacturing means for microreplication is a well-known technique. As the requirements imposed on the accuracy of injection-molded products to be manufactured increase, the technology reaches the natural limits of the polymer processing industry. In particular, the increasing requirements for the shape and position errors of injection-molded products manufactured by injection molding cannot be appropriately realized by the conventional methods. For example, when trying to align the front and back surfaces of an injection mold for injection molding with each other, at present, injection-molded products can only be manufactured with an error of about 10 micrometers.

[0002] For injection-molded products used in specific industrial fields such as information technology, laser technology, or communication network technology, these orders are unacceptably high. This is because the accuracy requirements for optical conductors in particular vary in the micrometer range or sub-micrometer range. With the conventional manufacturing methods in mechanical engineering, it is no longer possible to achieve improvements through more accurate manufacturing based on the manufacturing errors of the equipment.

[0003] In order to enable injection-molded products to be formed with enhanced accuracy, injection molding technology can be extended by the methods of the semiconductor industry.

[0004] Since the manufacturing methods and approaches of mechanical engineering and the semiconductor industry are basically different from each other, the manufacturing methods or achievable accuracies cannot be arbitrarily scaled. In other words, in the semiconductor industry, in particular, accuracies or surface qualities that were conventionally impossible to finish can be achieved. However, since the methods of the semiconductor industry have the possibility of dimension scaling (length: first order, area: second order, volume: third order), they cannot be transferred to mechanical engineering.

[0005] This opens up the possibility of further commercialization of novel injection-molded products. In particular, the alignment of the mold or, in some cases, the inserts inserted therein, has conventionally been carried out with insufficient accuracy. Usually, in order to transfer the desired structure to the injection-molding material that will later cure in the mold, a mold having corresponding mold surfaces or inserts with corresponding mold surfaces is used.

[0006] In this case, the alignment of the mold or the insert is carried out in the open state, and in this open state, two or more mold halves or mold parts do not yet provide an injection-molding space for the injection-molding material that will later be introduced therein. After each mold has transitioned to the closed state for injection molding, it is no longer possible to align the mold half or the one / more inserts arranged in the injection-molding space with each other. That is, alignment errors, especially those that need to be corrected with respect to the high requirements for micro-injection-molded products, can only occur in the open state of the mold. Alignment errors of the mold or the one / more inserts may occur again when the mold is closed or after it is closed. Therefore, in particular, mass production of injection-molded products using the same mold or the one / more same inserts for injection molding cannot be carried out with sufficient accuracy.

[0007] Therefore, the object of the present invention is to show an apparatus and a method that at least partially, and in particular completely, eliminate the disadvantages of the prior art. Furthermore, the object of the present invention is to show an improved apparatus for injection molding and an improved method for injection molding.

[0008] In particular, the object of the present invention is to show an apparatus and a method for improving the manufacturing accuracy of the injection-molded products to be manufactured.

[0009] This problem is solved by the features described in the parallel claims. Advantageous improvements of the invention are described in the dependent claims. Within the framework of the invention, all combinations consisting of at least two features described in the description, the claims and / or the drawings are also included. In the numerical ranges described, the numerical values within the described ranges are also considered to be disclosed as limit values and shall be claimable in any combination.

[0010] Thus, the present invention relates to an apparatus for injection molding, in particular for micro-injection molding, comprising at least - a mold having a first mold half and a second mold half, wherein the first mold half and the second mold half define an injection molding space in the closed state of the mold, and - at least one insert arranged in the injection molding space, wherein the at least one insert contains at least partially a polymer. The present invention relates to an injection molding apparatus having the above.

[0011] The apparatus has at least one insert that contains at least partially a polymer. The apparatus may have two or more inserts that contain at least partially a polymer.

[0012] The at least one insert is preferably alignable in the closed state of the mold, particularly with respect to another insert.

[0013] Furthermore, the present invention relates to a method for injection molding, in particular for micro-injection molding, wherein an injection molding space is defined in the closed state of a mold having a first mold half and a second mold half, and at least one insert arranged in the injection molding space contains at least partially a polymer.

[0014] Two or more inserts that contain at least partially a polymer may be arranged in the injection molding space.

[0015] Preferably, at least one insert is aligned in the injection molding space in the closed state of the mold, particularly with respect to another insert.

[0016] In one particularly preferred embodiment according to the invention, at least one insert has an elastic surface made of a structured and patterned polymer, in particular produced by imprint lithography. In other words, at least one insert or its surface may form a structured soft punch that is used as a master for the prototype of the injection molded part.

[0017] This elastic surface made of a structured and patterned polymer is hereinafter only referred to as an elastic structure. In one particularly preferred embodiment according to the invention, the insert consists of a substrate (English: back plane), in particular a plate, more preferably a wafer, on which the polymer to be structured is deposited and embossed, thereby forming an elastic structure. In this case, at least one insert is a component group consisting of at least two components, namely a substrate and a soft punch embossed thereon. The substrate is particularly used as a support substrate for the soft punch.

[0018] In particular, it is assumed that at least one insert consists at least in part of a polymeric elastic material.

[0019] In one special embodiment, at least one insert consists at least in part of an elastomer.

[0020] In one particularly preferred embodiment, the insert, in particular the elastic structure, is made of the following materials, namely · silicone · vinyl functional polymer · vinyl-terminated polydimethylsiloxane, in particular CAS: 68083-12-2 · vinyl-terminated diphenylsiloxane-dimethylsiloxane copolymer, in particular CAS: 68951-96-2 · Vinyl-terminated polyphenylmethylsiloxane, especially CAS: 225927-21-9 · Vinylphenylmethyl-terminated vinylphenylsiloxane-phenylmethylsiloxane copolymer, especially CAS: 8027-82-1 · Vinyl-terminated trifluoropropylmethylsiloxane-dimethylsiloxane copolymer, especially CAS: 68951-98-4 · Vinylmethylsiloxane-dimethylsiloxane copolymer, trimethylsiloxy-terminated, especially CAS: 67762-94-1 · Vinylmethylsiloxane-dimethylsiloxane copolymer, silanol-terminated, especially CAS67923-19-7 · Vinylmethylsiloxane-dimethylsiloxane copolymer, vinyl-terminated, especially CAS: 68083-18-1 · Vinyl rubber · Vinyl Q resin dispersion, especially CAS: 68584-83-8 · Vinylmethylsiloxane homopolymer, especially CAS: 68037-87-6 · Vinyl T-structure polymer, especially CAS: 126681-51-9 · Monovinyl-functionalized polydimethylsiloxane, symmetric or asymmetric, especially CAS: 689252-00-1 · Vinylmethylsiloxane terpolymer, especially CAS: 597543-32-3 · Vinylmethoxysiloxane homopolymer, especially CAS: 131298-48-1 · Vinylethoxysiloxane homopolymer, especially CAS: 29434-25-1 · Vinylethoxysiloxane-propylethoxysiloxane copolymer · Hydride-functional polymer · Hydride-terminated polydimethylsiloxane, especially CAS: 70900-21-9 · Polyphenylmethylsiloxane, hydride-terminated · Methylhydrosiloxane-dimethylsiloxane copolymer, trimethylsiloxy-terminated, especially CAS: 68037-59-2 · Methylhydroxysiloxane-dimethylsiloxane copolymer, hydride-terminated, especially CAS: 69013-23-6 · Polymethylhydroxysiloxane, trimethylsiloxy-terminated, especially CAS: 63148-57-2 · Polyethylhydroxysiloxane, triethylsiloxy-terminated, especially CAS: 24979-95-1 · Polyphenyl-dimethylhydroxysiloxysiloxane, hydride-terminated · Methylhydroxysiloxane-phenylmethylsiloxane copolymer, hydride-terminated, especially CAS: 115487-49-5 · Methylhydroxysiloxane-octylmethylsiloxane copolymers and terpolymers, especially CAS: 68554-69-8 · Hydride Q resin, especially CAS: 68988-57-8 · Silanol-functional polymer · Silanol-terminated polydimethylsiloxane, especially CAS: 70131-67-8 · Silanol-terminated diphenylsiloxane-dimethylsiloxane copolymer, especially CAS68951-93-9 and / or CAS: 68083-14-7 · Silanol-terminated polydiphenylsiloxane, especially CAS: 63148-59-4 · Silanol-terminated polytrifluoropropylmethylsiloxane, especially CAS: 68607-77-2 · Silanol-trimethylsilyl modified Q resin, especially CAS: 56275-01-5 · Amino-functionalized silicone · Aminopropyl-terminated polydimethylsiloxane, especially CAS: 106214-84-0 · N-Ethylaminoisobutyl-terminated polydimethylsiloxane, especially CAS: 254891-17-3 · Aminopropylmethylsiloxane-dimethylsiloxane copolymer, especially CAS: 99363-37-8 · Aminoethylaminopropylmethylsiloxane-dimethylsiloxane copolymer, especially CAS71750-79-3 · Aminoethylaminoisobutylmethylsiloxane-dimethylsiloxane copolymer, especially CAS: 106842-44-8 · Aminoethylaminopropylmethoxysiloxane-dimethylsiloxane copolymer, especially CAS: 67923-07-3 · Hindered amine functional siloxanes · Tetramethylpiperidinyl oxypropylmethylsiloxane-dimethylsiloxane copolymer, especially CAS: 182635-99-0 · Epoxy functional silicone · Epoxypropoxypropyl terminated polydimethylsiloxane, especially CAS: 102782-97-8 · Epoxypropoxypropylmethylsiloxane-dimethylsiloxane copolymer, especially CAS: 68440-71-7 · Epoxypropoxypropyl terminated polyphenylmethylsiloxane, especially CAS: 102782-98-9 · Epoxypropoxypropyldimethoxysilyl terminated polydimethylsiloxane, especially CAS: 188958-73-8 · Tris(glycidoxypropyl dimethylsiloxy)phenylsilane, especially CAS: 90393-83-2 · Mono-(2,3-epoxy)-propyl ether terminated polydimethylsiloxane, especially CAS: 127947-26-6 · Epoxycyclohexylethylmethylsiloxane-dimethylsiloxane copolymer, especially CAS: 67762-95-2 · (2-3% Epoxycyclohexylethylmethylsiloxane)(10-15% Methoxypolyalkyleneoxymethylsiloxane)-dimethylsiloxane terpolymer, especially CAS: 69669-36-9 · Alicyclic epoxy silanes and silicones · Epoxycyclohexylethylmethylsiloxane-dimethylsiloxane copolymer, especially CAS: 67762-95-2 · (2 - 3% epoxycyclohexylethylmethylsiloxane)(10 - 15% methoxypolyalkyleneoxymethylsiloxane)-dimethylsiloxane terpolymer, especially CAS:69669-36-9 · Epoxycyclohexylethyl-terminated polydimethylsiloxane, especially CAS:102782-98-9 · Carbinoal-functionalized silicone · Carbinoal hydroxyl-terminated polydimethylsiloxane, especially CAS:156327-07-0, CAS:104780-66-7, CAS:68937-54-2, CAS:161755-53-9, CAS:120359-07-1 · Bis(hydroxyethyl)amine-terminated polydimethylsiloxane · Carbinoal-functionalized methylsiloxane-dimethylsiloxane copolymer, especially CAS:68937-54-2, CAS:68957-00-6, CAS:200443-93-2 · Monocarbinoal-terminated polydimethylsiloxane, especially CAS:207308-30-3 · Monodicarbinoal-terminated polydimethylsiloxane, especially CAS:218131-11-4 · Methacrylate and acrylate-functionalized siloxane · Methacryloxypropyl-terminated polydimethylsiloxane, especially CAS:58130-03-3 · (3-Acryloxy-2-hydroxypropoxypropyl)-terminated polydimethylsiloxane, especially CAS:128754-61-0 · Acryloxy-terminated ethylene oxide-dimethylsiloxane-ethylene oxide ABA block copolymer, especially CAS:117440-21-9 · Methacryloxypropyl-terminated branched polydimethylsiloxane, especially CAS:80722-63-0 · Methacryloxypropylmethylsiloxane-dimethylsiloxane copolymer, especially CAS:104780-61-2 · Acryloxypropylmethylsiloxane-dimethylsiloxane copolymer, especially CAS:158061-40-6 · (3 - acryloxy - 2 - hydroxypropoxypropyl)methylsiloxane - dimethylsiloxane copolymer · Methacryloxypropyl T - structured siloxane, especially CAS: 67923 - 18 - 6 · Acryloxypropyl T - structured siloxane · Polyhedral oligomeric silsesquioxane (POSS) · Tetraethyl orthosilicate (TEOS) · Poly(organo)siloxane · Polyhedral oligomeric silsesquioxane (POSS) · Polydimethylsiloxane (PDMS) · Tetraethyl orthosilicate (TEOS) · Poly(organo)siloxane (silicone) · Perfluoropolyether (PFPE) consists of at least one of the above.

[0021] In particular, it is assumed that at least one insert is inserted into the first mold half or the second mold half in the open state of the mold, especially being position - fixed. The mold has an injection - molding space formed by the first and second mold halves inside in the closed state.

[0022] At least one insert is arranged in the injection - molding space and is preferably alignable. In this way, the alignment of at least one insert can be advantageously carried out in the closed state of the mold, and the alignment error can be corrected.

[0023] In this case, in particular, it is assumed that at least one insert is movable relative to the mold or the injection - molding space in one or more directions. Preferably, the alignment error is detected by measuring the injection - molded product produced by injection molding.

[0024] The apparatus and the method are preferably designed for mass-producing injection-molded articles that are subject to particularly high requirements with respect to molding accuracy. In particular, by means of the apparatus and the method, injection-molded articles having functional regions can be manufactured. These functional regions are molded in the injection-molded article, in particular during the curing of the injection-molded material introduced into the mold, by means of at least one insert that can be particularly aligned.

[0025] In one preferred embodiment of the invention, the apparatus has at least one further insert arranged in the injection-molding space, where it is assumed that the insert and / or at least one further insert can be aligned in the closed state of the mold. In this way, the injection-molded article may be molded or manufactured using a plurality of inserts.

[0026] Furthermore, each insert can preferably be aligned relative to one another in the closed state of the mold. In addition to the flexible shaping of the injection-molded article, an exact alignment with respect to manufacturing is preferably made possible by aligning two inserts. In this embodiment, in particular, one insert is arranged in the first mold half and at least one further insert is arranged in the second mold half.

[0027] In another preferred embodiment of the invention, it is assumed that the insert and / or at least one further insert each have a molding surface with an elastic structure. By means of the molding surface, the shape of the injection-molded article can preferably be preset.

[0028] Due to the elastic structure, in particular, particularly small, in particular microstructures and / or nanostructures can be molded onto the injection-molded article by means of the injection molding method. The elasticity of the structure enables a finer and more accurate molding of the structure in the injection-molded article.

[0029] In particular, the shape forming the tooth row or the undercut can also be molded. When the rigid structure is demolded, there is a risk of destroying the micro-structure and / or the nano-structure or being destroyed itself. Examples include inclined micro-structures and / or nano-structures.

[0030] Using such a structured molding surface, preferably, a plurality of injection molded products with extremely high requirements can be mass-produced by injection molding. Thereby, a manufacturing method capable of manufacturing injection molded products inexpensively, quickly, and with high quality is shown.

[0031] The elastic structure preferably consists of a polymer used for a soft punch in the semiconductor industry. Such polymers are described, for example, in each of the publications of International Publication No. 2015078520 and International Publication No. 2014202127.

[0032] In another preferred embodiment of the present invention, it is assumed that the molding surface of at least one insert and the molding surface of at least one other insert can be aligned with each other in the closed state of the mold. By aligning the molding surfaces of the inserts with each other, advantageously, the shape of the injection molded product can be set extremely accurately. By aligning the molding surfaces of the inserts that can be aligned with each other in the closed state of the mold, advantageously, the position or location of the molding surfaces relative to each other can be set particularly accurately.

[0033] In another preferred embodiment of the present invention, it is assumed that the structure of the molding surface of at least one insert and the structure of the molding surface of at least one other insert can be aligned with each other in the closed state of the mold.

[0034] By aligning the elastic structures arranged on the mold-taking surface, it is possible to advantageously and accurately adjust the positions of the structures molded on the front and back surfaces of the injection-molded product relative to each other. In particular, for some applications, not only are specific shapes and structures molded particularly accurately on the injection-molding material or the injection-molded product, but also the respective positions of the molded shapes and structures relative to each other are required to be molded as accurately as possible on the injection-molded product.

[0035] In another preferred embodiment of the present invention, at least one of the mold halves and / or at least one insert and / or at least one other insert and / or each structure incorporates at least one heater, whereby it is assumed that the injection-molding space, particularly the injection-molding material guided into the injection-molding space, can be accurately heated by the at least one heater.

[0036] The heater can be of any type. For example, a resistance heating heater or an induction heater is conceivable. By induction heating, the mold or one or more inserts, particularly the interface surface of the mold-taking surface having an elastic structure that comes into direct contact with the injection-molding material during injection molding, can be advantageously heated. In this way, it is possible to prevent the unregulated solidification of the injection-molding material, particularly in the fine structure of the mold-taking surface of the insert, and the liquid injection-molding material can be advantageously heated and held uniformly in a single injection-molding process. Furthermore, the quality of the mold-taking is improved or shape errors in the injection-molded product to be manufactured are prevented. In particular, the mold-taking of microstructures and / or nanostructures is improved and simplified by the heated mold-taking surface or the heated structure.

[0037] In one particularly preferred embodiment according to the present invention, the heater is incorporated into at least one insert. When at least one insert is a semiconductor, the heater is directly formed as an active component. That is, a metal conductor path or semiconductor element suitable for efficiently converting current into Joule heat is directly manufactured within at least one insert. This enables extremely efficient heating. The heater is preferably formed in the same manner as described in the publication of International Publication No. 2019 / 210976.

[0038] In another preferred embodiment of the present invention, it is assumed that at least one insert and / or at least one other insert has a plurality of alignment marks, particularly on each form-taking surface and / or each back surface. An alignment mark is a mark that can be arranged corresponding to a predetermined position of the insert.

[0039] In particular, these are regularly arranged alignment marks, particularly an alignment mark field, within which each alignment mark can be arranged corresponding to a predetermined position within the alignment mark field. The alignment marks on the form-taking surface may in particular be structures arranged on the form-taking surface of at least one insert.

[0040] Preferably, at least one insert has alignment marks on the form-taking surface and the back surface. Particularly preferably, the positions of the alignment marks on the form-taking surface relative to the positions of the alignment marks on the back surface of at least one insert are known to each other.

[0041] The alignment marks can preferably be detected and processed by optical alignment means and correlated with each other. The alignment means may be arranged, for example, within a mold, particularly on the back side of at least one insert. The alignment marks enable particularly accurate and easy alignment of at least one insert.

[0042] In another preferred embodiment of the present invention, the first mold half and / or the second mold half has an inspection window, whereby it is assumed that at least one insert and / or at least one other insert can be aligned in the closed state of the mold based on a plurality of alignment marks and / or can be aligned with each other. The inspection window, which may also be a plurality of inspection windows, is arranged in the mold such that the alignment marks of at least one insert and / or at least one other insert are visible or detectable from outside the mold, particularly with respect to optical alignment means.

[0043] In this way, one or more inserts can be aligned / aligned with each other. Preferably, the inspection window is arranged in the mold such that at least the alignment marks on the back of at least one insert are visible in the closed state of the mold. Thereby, advantageously, a monitored relative alignment of each insert can be carried out.

[0044] In another preferred embodiment of the present invention, the first mold half and / or the second mold half each has at least one positioning mechanism, whereby it is assumed that at least one insert and / or at least one other insert can be aligned in the closed state of the mold based on a plurality of alignment marks. The positioning mechanism is particularly automated or computer-controlled and can advantageously carry out the alignment of at least one insert and / or at least one other insert with the mold in a closed state.

[0045] In this case, the alignment is preferably carried out based on alignment marks. In particular, the positioning mechanism is designed such that at least one insert or a plurality of inserts can be aligned particularly accurately. Preferably, the positioning mechanism is an aligner. The insert to be aligned is fixed in position within the mold but can be aligned by the positioning mechanism. In this way, at least one insert can be aligned, preferably based on the alignment marks even when the mold is closed.

[0046] In another preferred embodiment of the present invention, it is assumed that based on a plurality of alignment marks provided on the back side of at least one insert and / or on the back side of at least one other insert, the structure of the molding surface of at least one insert and the structure of the molding surface of at least one other insert can be aligned with each other in the closed state of the mold. In this embodiment, the position of the alignment marks on the back side of at least one insert relative to the structure on the molding surface of at least one other insert is known. In this way, preferably in the closed state of the mold, the inserts and / or a plurality of inserts, in particular the structures important for molding on the injection molded product, can be aligned or mutually aligned only based on the alignment marks on each back side. In this way, preferably, the alignment of the structures on the molding surface of the insert is possible only based on the alignment marks on the back side. For example, the alignment based on the alignment marks on the back side of the insert can also be carried out during injection molding.

[0047] In another preferred embodiment of the method according to the invention, it is envisaged that at least one insert and at least one further insert arranged in the injection molding space are aligned with each other in the injection molding space in the closed state of the mold, in particular the molding surfaces of at least one insert and / or the molding surfaces of at least one further insert. In this way, it is also possible to align or align with each other the molding surfaces of the respective inserts, in particular the structures arranged on the molding surfaces, by means of the method. As a result, advantageously, the shape accuracy of the injection molded part produced during injection molding is increased.

[0048] In another preferred embodiment of the method according to the invention, it is envisaged that at least one insert and / or at least one further insert are aligned on the basis of a plurality of alignment marks attached to the insert and / or at least one further insert. In this way, advantageously, at least one insert and / or at least one further insert can be aligned on the basis of the alignment marks.

[0049] In another preferred embodiment of the method according to the invention, it is assumed that the alignment of at least one insert and / or at least one further insert is carried out based on the measurement of an injection-molded part produced by an injection molding method. After producing the injection-molded part, it can be measured and analyzed. At this time, the actual values of the shape or geometry of the injection-molded part are compared with the target values. From this comparison, shape errors can be identified and corrections can be derived. By realigning one or more inserts multiple times, this error can be iteratively improved, especially until the shape error is within a preset manufacturing error range. Preferably, the structure arranged on the mold parting surface measures the area of the injection-molded part to be molded. This is because these areas are particularly important for the functionality of the produced injection-molded part. In this way, an improvement in alignment can be achieved based on the produced injection-molded part.

[0050] In another preferred embodiment of the method according to the invention, it is assumed that the alignment is carried out by post-processing at least one insert and / or at least one further insert. Based on the detected shape error, corrections are carried out by aligning one or more inserts. The alignment may be achieved by post-processing the corresponding material, in particular by removal or deposition. For example, if the inserts are positioned opposite each other, shape errors in the injection-molded part may occur based on the inaccurate parallelism between the inserts. This can be done in particular by removing the material of the insert, especially on the back side. For this purpose, for example, a laser beam may be used. Advantageously, in this way, shape errors in the injection-molded part that cannot be compensated for by alignment using, for example, a positioning mechanism can be compensated for.

[0051] In another preferred embodiment of the method according to the invention, it is assumed that the method has at least the following steps, in particular in the following order. That is: i) mounting an insert and / or at least one further insert in a mold; ii) closing the mold; iii) producing an injection molded article, in particular by introducing an injection molding material and curing the injection molding material; iv) removing and measuring the injection molded article; v) identifying an alignment error by comparing with a target value; vi) aligning the insert and / or at least a second insert.

[0052] In this way, the injection molding method can be advantageously adapted, preferably iteratively, to a process based on the alignment of the insert.

[0053] One aspect of the invention is based on a modification of an injection molding method or an injection molding device, by means of which a surface having a micrometer or nanometer structure can be formed, in particular with an at least partially flexible insert and in particular with an insert surface structured by a soft punching technique. To improve the injection molding accuracy, an approach of the semiconductor industry is applied, by means of which each mold part or each mold take-off surface is aligned or aligned with each other. Based on the measurement and feedback of the produced injection molded article or final product, the accuracy of the manufacturing method can be increased or adapted. In this context, feedback means that a large number of injection molded articles produced are measured several times and, optionally, errors of the injection molded articles that can be confirmed thereby are compensated by aligning the insert and / or by post-processing the insert, whereby the quality of each injection molded article produced can be improved iteratively.

[0054] Based on the device according to the present invention and the method according to the present invention, it becomes possible to functionalize the surface of the molded workpiece. As a result, by optimizing the manufacturing method at any given time, the manufacturing cost can be reduced while the accuracy of the workpiece is increased. In other words, the conventional manufacturing method can be used for shaping. In particular, the surface functionalization is achieved in the mold by at least one new high-precision insert. The production of injection-molded articles with functional surfaces or microstructured and / or nanostructured surfaces has hitherto been impossible with conventional injection molding devices or injection molding methods.

[0055] The present invention relates to an injection molding method and an injection molding device, in particular a micro injection molding method and a micro injection molding device. That is, it relates to the production of injection-molded articles in which the mold-taking surface has a micro-structure for taking the mold of the injection molding material or the corresponding injection-molded article.

[0056] A well-known injection molding device is designed such that the accuracy and / or shape-position error and / or surface quality and / or surface functionalization of the produced injection-molded article are improved, in particular at least partially by an elastic, preferably microstructured insert.

[0057] In injection molding, generally, the injection-molded article is produced in a mold in a prototype or an injection molding space (also referred to as an injection molding chamber), and in this case, the mold is filled with an injection molding material. In this case, the injection molding material has specific state variables with respect to a specific volume, temperature, and filling pressure. The mold is filled with a compressible injection molding material heated and compressed above the melting temperature of the injection molding material under high pressure and then repressurized. The temperature of the injection molding material is particularly 10°C, preferably 25°C, more preferably 50°C, and most preferably 75°C higher than the melting temperature of the injection molding material. The melt solidifies in a repressurized state in the mold. After the phase transition to the solid state (with the inevitable shrinkage physically caused) and particularly after the pressure in the mold reaches atmospheric pressure, the mold is opened at at least one mold separation plane, and the injection-molded article is taken out or automatically dropped.

[0058] The achievable dimensional stability of injection molded articles is ensured by materials, temperature, pressure whose states can vary, as well as the shaping and / or functionalization of the mold.

[0059] The disclosed first injection molding device has at least one modified mold that includes at least one insert for the adaptation and / or functionalization of the mold and thus of the injection molded article to be produced.

[0060] The insert preferably has a surface that is shaped during the production of the injection molded article, in particular a microstructured or nanostructured surface.

[0061] Particularly preferably, at least one insert has a coating, preferably a structured coating, particularly preferably a microstructured or nanostructured coating, and this coating is shaped during the production of the injection molded article.

[0062] Preferably, at least one insert has an elastic structured part that particularly has a microstructure and / or nanostructure. That is, an insert that is at least partially rigid and has a flexible structure on its surface can achieve an improved shaping of the injection molded article with high precision, high requirements for the surface structure, and / or with a small shape and position error.

[0063] Preferably, the shape and design of the mold and / or at least one insert determine at least a rough shaping, and the particularly elastic structured part of the insert surface that is shaped in the injection molded article determines the surface of the injection molded article or the functionalized part of the surface of the injection molded article, thereby causing a functional separation between at least a rough shaping and the functionalization of at least one product surface.

[0064] It is conceivable that at least one insert, in particular a microstructured or nanostructured insert, has an additional local heater incorporated therein, whereby faithful replication of the mold can be improved and a higher so-called shape factor (aspect ratio) can be obtained, that is, a more advanced and narrower structure can be formed.

[0065] Similarly, it is also conceivable to connect the heater to the surface-structured part of at least one insert, whereby the injection molding material can be heated accurately and directly in the region in contact with the injection molding material. Thereby, the shape factor of the structured replication surface can be further improved.

[0066] The mold of the injection molding apparatus according to the present invention has a particularly unique invention. The parts of the mold that are not the most important with respect to the function of the injection molded product can be designed to comply with ISO2768-1 and ISO2768-2 according to the conventional manufacturing method, and are particularly classified as "fine" or "high".

[0067] The mold has at least one insert. At least one insert can be coated on at least the replication surface of the insert by an embossing method, and thus can be functionalized.

[0068] At least one insert, which is subject to relatively high requirements for functionalization of surface characteristics, in particular microstructured periodic surface structures, etc., is preferably manufactured by a so-called microreplication, in particular an embossing method of micro-lithography or nano-lithography, and is incorporated into the mold as at least a partially elastic insert. Based on this surface coating by the embossing method, at least a partially elastic structure provided on at least one insert can be advantageously replicated onto the injection molded product individually and accurately.

[0069] The surface structure of at least one insert is formed on each insert, for example, by lithographic imprint technology, in the same way as the technology described in detail in the publication of European Patent No. 2870510.

[0070] At least one insert, which may include, for example, an inorganic carrier, preferably a semiconductor material, and / or particularly preferably silicon nitride (Si3N4) and / or silicon carbide (SiC) and / or diamond and / or industrial glass, is preferably mounted in the mold in an alignable manner. Thus, although at least one insert is locally fixed in position, it may be precisely moved and thus fixed in another position and supported.

[0071] It is also conceivable to first form an elastic structure on a support using well-known imprint lithography technology and then transfer it to the surface of at least one insert. For the transfer of the structure, plasma activation and / or adhesives may be used in particular. Preferably, however, the elastic structure is formed directly on the surface of at least one insert. An aligner may be used to align and / or pre-position the structured part on the surface of at least one insert. In this case, for example, a processing laser may be used or incorporated into the mold to attach the support to at least one insert.

[0072] In one particularly preferred and advantageous embodiment of the mold, it is possible to align and fix at least one insert in the mold using an aligner known from semiconductor technology. In this case, the alignment accuracy of at least one insert in the mold is better than 5 micrometers, preferably better than 1 micrometer, particularly preferably better than 500 nanometers, and extremely particularly preferably better than 250 nm, especially in the lateral plane of the mold. The same alignment accuracy in another movement direction of the mold can be provided by the aligner or another aligner.

[0073] Preferably, the alignment accuracy of at least one insert in the mold is measured in the manufactured injection molded product. That is, in a mass production process, one or more first injection molded products manufactured are measured, and thus the alignment accuracy can be specified by comparing the measured actual value with a preset target value.

[0074] Preferably, an aligner is incorporated into the injection molding apparatus as an alignment module. Therefore, in a modular configuration format, an apparatus having a plurality of modules such as a measurement module for measuring an injection molded product, a material preparation module, etc. can be flexibly added according to the application needs of the injection molding apparatus.

[0075] In particular, it is conceivable to modify the so-called mask aligner in the semiconductor industry, and thereby an existing optical system that generates monochromatic UV rays can be used. Therefore, it is also conceivable that the injection molding apparatus has an aligner and an imprinter for forming a particularly elastic microstructured or nanostructured surface on the insert.

[0076] More preferably, at least one insert is aligned in an aligner combined in the mold, and in particular, it is conceivable to pre-fix it in the mold using high-energy radiation, in particular a laser or a heater. As a result, an insert provided with an elastic surface coating is fixed at an accurate position in the mold, and the mold can be moved.

[0077] The fixing causes a combination of at least one insert and a mold adapted or designed to match the operating conditions (overpressure exceeding at least 2000 bar, preferably exceeding 2400 bar, mold pressing material and mold temperature exceeding 150 degrees Celsius, preferably exceeding 200 degrees Celsius). By the fixing, at least one insert is fixed at an accurate location in the mold, particularly arbitrarily.

[0078] The arbitrary fixation of at least one insert within the mold exactly means that six degrees of freedom of movement are taken away from at least one insert. Advantageously, this avoids deformation of the insert due to parasitic forces.

[0079] The alignment accuracy between inserts is also measured in the injection molded article, and those skilled in the art refer to it as the resulting alignment error. That is, the alignment error occurs relatively between the insert and the second component, particularly another insert.

[0080] Particularly in an injection molded article, the alignment error measured relatively for two inserts facing each parting surface is preferably less than 10 micrometers, preferably less than 5 micrometers, particularly preferably less than 1 micrometer, most particularly preferably less than 500 nanometers, and most preferably less than 200 nanometers.

[0081] For special, particularly optical applications, a smaller alignment error is required. That is, the alignment error in the injection molded article is less than 150 nanometers, preferably less than 100 nanometers, and particularly preferably less than 50 nanometers.

[0082] When a periodic, preferably identical or periodically repeated structure is molded in the injection molded article, it is important for functionality to align the periods with each other.

[0083] Whether the periods are aligned as "peak to peak", or "valley to valley" or "valley to peak" with each other is not important for considering the periodic error in the injection molded article. That is, the periodic error is regarded as the deviation from the ideal, preset alignment state.

[0084] This deviation, that is, the error of the injection molded product alone is important. Therefore, advantageously, it is possible to indicate the alignment state between cycles as a quality characteristic. The alignment error for exactly one cycle only causes an error at the edge of the mold pressing structure of the injection molded product, in other words, it only causes an error shifted by the length of one cycle.

[0085] In this case, the alignment error measured in the injection molded product, particularly the cycle error, is desirably less than 0.25 cycles, preferably less than 0.1 cycle, and particularly preferably less than 0.05 cycle.

[0086] The alignment error must also be minimized with respect to rotation. Over a distance of 50 mm, it is desirable that the structure does not differ by more than 1.0 μm. This corresponds to a maximum angle of 2*10 -5 °. Therefore, the alignment error with respect to the angle is less than 2*10 -5 °, preferably less than 10 -5 °, more preferably less than 5*10 -6 °, most preferably less than 2*10 -6 °, and most preferably less than 2*10 -7 °.

[0087] In other words, the rotational error at a reference length of 50 mm measured at the circumference and / or edge of the product is less than 1 μm, preferably less than 500 nm, particularly preferably less than 250 nm, extremely particularly preferably less than 100 nm, and most preferably less than 10 nm.

[0088] In one preferred embodiment of the injection molding apparatus, the injection molding material may contain a photosensitive curable, particularly UV curable, component. When such an injection molding material is used, instead of the curing or phase transition of the injection molding material from a liquid to a solid due to heat, a phase transition based on UV rays is performed.

[0089] The mold in this embodiment of the injection molding apparatus has an irradiation window that is transparent to the incorporated radiation source and / or the curing radiation, and irradiates the injection molding material with the curing radiation through the irradiation window to initiate curing thereby. In one preferred embodiment, the mold is transparent.

[0090] As the injection molding material, industrial polymers and / or general-purpose plastics, in other words polymers by mass production, can be used. In this case, the material selection follows the use of the injection molded article.

[0091] Polymers and / or mixtures and / or blends of polymers with or without fillers can be used, in particular the following materials, namely, - POSS - polyethylene (LDPE, HDPE) and / or - polypropylene (PP, chlorinated PVC) and / or - polystyrene, and / or - methacrylate (PMMA), and / or - terephthalate (PET), and / or - fluorinated polymers (PTFE), and / or - TPO, CAB, ABS, PA-66, POM, PC, PPS, PES, LCP, PEEK, PF, UF, UP, EP, PIB and / or PIM may be included.

[0092] The shrinkage of the injection molding material used is preferably less than 5%, particularly preferably less than 3%, even more preferably less than 1.7%, and most preferably less than 0.7%.

[0093] The second embodiment of the injection molding apparatus includes at least one modified mold with two inserts to be aligned with each other, and the inserts perform the functionalization of the injection molded article with a surface that is particularly elastic, preferably microstructured and / or nanostructured.

[0094] In this embodiment of the injection molding device, at least two inserts having an elastic, microstructured and / or nanostructured insert surface can be aligned and fixed to each other within the mold.

[0095] The alignment accuracy of the inserts within the mold is of the same order as the accuracy of aligning one insert within the mold.

[0096] It is possible to arrange each insert within the mold such that each insert is included in a different mold half of the split plane of the mold. In this way, the injection molding device and the injection molding method can be configured particularly flexibly with respect to the position of the inserts within the mold.

[0097] In order to carry out the alignment process of the inserts with high accuracy, it is possible that the mold is at least partially transparent. In other words, the mold may have a removable support part used for force transmission and uniform force distribution of the pressing pressure, and an inspection window or alignment window through which the mold can align the insert or the structured surface of the insert in a completely closed state. The mold may have a corresponding support structure so that the force and temperature fluctuations during the injection molding process can be absorbed by the elastic, microstructured insert as well as the inspection window and / or alignment window. The inspection window may be formed particularly for curing the injection molding material by UV rays.

[0098] In order to perform precise alignment of one or more inserts within at least two mold halves of the mold, it is necessary to align the inserts within the closed mold. In this way, it is possible to compensate or correct the alignment error of one or more inserts that occurs during or already exists at the time of closing the mold or during fixing within the mold.

[0099] Alignment may be performed, for example, by so-called alignment marks or markings. These are attached to one or more inserts. Preferably, at least one marking is attached to each insert that can be aligned in the closed state of the mold.

[0100] Alignment is preferably performed by optically aligning at least one marking arranged on the back surface of one insert with an alignment mark arranged on the back surface of another insert. That is, alignment may advantageously be performed via the back surface of the insert on the side opposite to each mold-taking surface.

[0101] The marking or alignment mark may include a cross, a propeller-shaped alignment mark, a circle, a polygonal pattern, a linear pattern for optical interference, a QR code, etc., which are common in the semiconductor industry.

[0102] Preferably, the alignment mark is arranged within a mark field. In this case, since each individual alignment mark has a predetermined information content, the position of the corresponding insert relative to the position within the mark field and thus relative to the optical alignment means is known. In this case, alignment may advantageously be performed relatively based on the known positions of the individual marks within the mark field.

[0103] It is particularly advantageous if the insert has alignment marks or markings on two surfaces located on opposite sides of each other. Preferably, the alignment marks or markings are located on each back surface of the insert and on the side of each mold-taking surface of the insert. In this way, alignment can advantageously be performed from both sides of the insert.

[0104] Very particularly preferably, the injection molding device has an aligner and a positioning means for two inserts. In this case, the aligner correlates a surface structuring formed on the mold clamping surface, which in particular functions as an alignment mark, with an alignment mark on the back surface of the insert, and this correlation is in particular based on image evaluation. Using the correlation data, a back-to-back alignment of at least two inserts can be carried out. In this case, the optical alignment means for detecting each alignment mark on the back surface may be arranged in the mold. Thus, the alignment of the inserts may advantageously be carried out in the closed state of the mold.

[0105] It is also conceivable that the alignment is carried out by alignment means arranged outside the mold and capable of detecting the alignment marks or markings of the insert via, for example, a passage or an alignment window.

[0106] The surface structuring of the insert can be carried out in particular in an aligned manner on the insert surface or the mold clamping surface, so that the position and location of a particularly soft surface structure can be measured. In this case, advantageously, the surface structuring can be used as an alignment mark or marking. In particular, it is conceivable that the insert has on its back surface another marking or alignment mark that can be measured relative to the surface structuring. In this way, when the marking is measured, the position of the surface structuring located on the opposite side also becomes known, and vice versa.

[0107] The insert may have different regions or different films of the surface structuring. These may include surface structuring to be molded and / or surface structuring not to be molded, in particular alignment marks. The surface structuring can be formed in a so-called "first print" or in continuous production.

[0108] In one advantageous embodiment of the device, markings, in particular alignment marks, may be attached and / or applied and / or provided on the surface of the insert, in particular the soft, to-be-molded structure, and on the surface of the insert located opposite thereto. In other words, the insert may have alignment marks and / or alignment mark fields on both surfaces, and the alignment marks and / or alignment mark fields qualify the insert for alignment in the aligner, in particular via lithography or an electron beam.

[0109] Preferably, the alignment marks of the surface structuring are measured with respect to the same surface of the insert, whereby the position of the surface structure in the insert can be confirmed.

[0110] Particularly advantageously, it is envisaged to measure and compare the alignment marks of the surface structuring of the insert with the alignment marks on the side of the surface structuring (embossing) that is not structured. In other words, the correlation of the surface structuring (in particular its position and / or location) with respect to the back of the insert is effected. Thereby, it is possible to align the surface structures of inserts that are not optically directly accessible to the aligner. By correlating the front of the insert with the back, each insert can be aligned with each other such that the surface structures are directly aligned with respect to the unstructured back of the insert.

[0111] Very particularly preferably, the alignment of the inserts is carried out within a closed mold.

[0112] Since all surface-structured inserts can be measured and correlated with each other, by better aligning the inserts with each other, the alignment error of the measured injection-molded part can be corrected based on an error correction vector derived from the alignment error of the injection-molded part.

[0113] The inspection result of alignment is obtained as a result of measurement of the manufactured injection molded product or detection of alignment error based on the manufactured injection molded product.

[0114] In particular, it is assumed that the insert can be positioned or aligned without play in a closed mold, in particular by a feed movement of less than 1000 micrometers, preferably less than 500 micrometers, particularly preferably less than 250 micrometers, via a solid joint.

[0115] In another preferred embodiment, an air bearing incorporated in the mold can improve the mobility of the insert. In this way, easy and extremely accurate alignment becomes possible.

[0116] In other words, the feed movement means the maximum movement distance of the insert in the mold when aligning.

[0117] As a result of the maximum movement distance or the maximum feed movement, the alignment mark covers at least one surface larger than the sum of the movement vectors of the positioning device or the alignment device. For example, when it is movable 1 mm in the x direction and also 1 mm in the y direction, it is desirable that the alignment mark exists on a surface larger than 1 mm within the field of view of the aligner. 2 It is desirable that it exists on a larger surface.

[0118] It is assumed that the insert can be positioned using a precision positioning device equipped with a piezo drive device and / or differential screw adjustment means, in particular.

[0119] For example, a piezo drive device, a linear piezo drive device, a threaded drive device, etc. can be used.

[0120] Furthermore, after the inserts are aligned with each other, they are preferably fixed in the mold such that the position and location of the inserts are adjusted by less than 1%, preferably by less than 50 ppm, and particularly preferably by less than 100 ppb, by a series of production of injection molded products or at least by production of statistically significant samples of injection molded products. The adjustment relates to the ideal values of the injection molded products to be produced. In other words, the variation in manufacturing errors regarding the location and / or position of the inserts is kept within a narrow manufacturing error range of less than 1%, preferably less than 50 ppm, and particularly preferably less than 100 ppb.

[0121] After the iterative correction of the position and location of the inserts in the mold, which results in minimizing manufacturing errors in the injection molded products as an effect, the inserts may be fixed in the mold, particularly for mass production.

[0122] In this case, "fixed" means that dissociation of the insert from the mold is impossible without damaging the insert (particularly based on high adhesion to the mold).

[0123] It is also conceivable that the fixed inserts need to be replaced. In this case, the inserts may be destroyed, but it is desirable that the functionality of the mold is maintained except for the necessary cleaning and that another insert can be accommodated without post-processing of the mold.

[0124] In one preferred embodiment of the mold in the injection molding device, it is assumed that the shape error and position error of the injection molded product, particularly by post-processing of at least one elastic surface structure of each insert and / or by post-processing of at least one of each insert, are advantageously improved, particularly by the method specifically disclosed. In particular, the parallel flatness of the injection molded product can be improved.

[0125] Furthermore, it is assumed that the arrangement of the mold or one or more inserts is adjusted by an iterative, particularly approximate, verification method.

[0126] Form a mold for manufacturing a particularly large number of injection molded products, especially for statistically important quantities.

[0127] Measure the injection molded products and, in particular, evaluate them statistically. In this way, advantageously, the average alignment error can be determined.

[0128] Subsequently, based on this, mold corrections, in particular insert adjustments, can be carried out. This correction may, for example, involve removing or adding material and / or changing the orientation and / or adapting the position of the insert.

[0129] Manufacture and evaluate the corrected injection molded products in particular for statistically important quantities. Continue to iteratively perform an approximation of the ideal injection molded product or start the production of injection molded products.

[0130] To continue to correct errors, a statistical evaluation of a random sample of injection molded products may be carried out, whereby the required adaptation can continue to be performed. In particular, the effects of mold deterioration and wear can be recognized early.

[0131] In other words, individual adaptation and adjustment are carried out for each mold of the injection molding device before mass production of the injection molded products, thereby improving the quality of the injection molded products and enabling a narrower manufacturing error of the injection molded products, especially in the area manufactured by microtechnology.

[0132] The first preferred, exemplary injection molding method is preferably carried out in the following steps, in particular in the following order. That is: - A step of mounting at least one elastic, microstructured or nanostructured insert on the mold, - A step of closing the mold, - A step of aligning and fixing the insert with the mold and / or the inserts, in particular the backs, with each other, especially in a particularly incorporated aligner (alignment module), and fixing them in the mold. - Incorporating the mold into an injection molding device, - Manufacturing at least one injection molded part, in particular by an injection molding method, - Removing the injection molded part from the mold, measuring it, in particular in a 3D coordinate measuring machine, and transferring the data to a data memory and a data analysis device, - Inspecting and / or testing the injection molded part with respect to its functionality in any method step, - Creating, by means of a computer, an error-vector field derived from the measured values and target values, and determining correction factors and correction means, - Applying accurate corrections, - Including, in the accurate corrections, changing the position and location of at least one insert in the mold, - Optionally, repeating the adjustment of the mold and the insert continuously.

[0133] One another preferred, exemplary injection molding method in particular has the following method steps in particular in the following order.

[0134] In a preparation method step, preparing the mold. For this purpose, it is necessary to functionalize the inserts by means of a surface structure. Measuring the correlation of each insert from the surface structure to the back, and processing it in particular in a computer as a data memory and a data analysis device. - Mounting elastic, microstructured or nanostructured inserts, in particular, on the mold, - Closing the mold, - Aligning the inserts with each other, in particular the backs, and fixing them in the mold, in particular in an aligner (alignment module) incorporated in the injection molding device, - Incorporating the mold into an injection molding device, - Manufacturing at least one injection molded part, in particular by an injection molding method, - Removing the injection molded part from the mold, measuring it, in particular in a 3D coordinate measuring machine, and transferring the data to a data memory and a data analysis device, - In any method step, inspecting and / or testing the injection molded article with respect to its function, - Using a computer to create an error - vector field derived from the measured values and target values, and determining the correction factors and correction means, - Applying the precise correction.

[0135] The correction may include at least a local material increase or at least a local material decrease or a change in the surface structuring. In particular, fluctuations or undulations in the thickness of the injection molded article can be changed by precise material removal or material increase on the back of the insert.

[0136] The press - in pressure occurring during injection molding can be used to precisely utilize the deformation occurring in the insert to at least locally influence the shape of the injection molded article.

[0137] When at least locally removing material from the back of the insert, the volume of the injection molded article increases. Thereby, local depressions in the injection molded article can be corrected.

[0138] When the material is locally increased at least on the back of the insert, the volume of the injection molded article decreases.

[0139] A person skilled in the art can use precise processing methods such as vapor deposition or PVD or CVD or molecular beam epitaxy for film formation, or can utilize a discontinuous support film. For film removal, electron beam removal or laser removal or hair burning or lapping or grinding or sandblasting or plasma treatment or treatment using an ion source is conceivable. In terms of alignment, a person skilled in the art can use any well - known processing method. - Incorporating the modified insert into the mold and starting the subsequent repeated production of the injection molded article until the interruption determination criterion is reached.

[0140] Possible interruption criteria are the attainment of qualitative and functional criteria for the injection-molded part. Another interruption criterion is the irreparable deterioration of the injection-molded part, as a result of which the mold and / or insert are to be inspected and replaced.

[0141] Another advantage, feature, and detail of the present invention will become apparent from the following description of the preferred embodiments with reference to the drawings.

Brief Description of the Drawings

[0142]

Figure 1

[0143] In the figure, the same reference numerals are given to the same components or components having the same function.

[0144] The mold 1 consists of a first mold half 2 and a second mold half 3 which may be separated from each other by a mold separation plane E. The technical design of the mold 1 determines the number of necessary mold parts and the number of mold separation planes. Necessary guides, fitting cones, as well as extrusion pins, media supply parts for cooling and / or heating, electronic component groups for heating, counterbores, and cutting tools for cutting off the filling passage, which are well known to those skilled in the art, are not shown.

[0145] The mold 1 has a first insert 5 and a second insert 5'. In the present invention, the inserts 5, 5' contain a polymer.

[0146] An inspection window 4 is shown in the second mold half 3, and the inspection window 4 separates the second mold half 3 from the injection molding space 10 and the insert 5' in particular in an airtight manner. Through the inspection window 4, the alignment mark 5m' of the insert 5' can be observed, in particular using an aligner (not shown), and can be adjusted by the positioning mechanism 6.

[0147] The pressure distributor 7 enables covering the inspection window 4 and / or the back 5b’ of the insert together with the alignment mark 5m’ during the injection process, so that the operating pressure during injection molding can be maintained, for example, at an overpressure of up to 2500 bar, without the risk of the injection molding material (not shown) leaking from the mold 1, especially without being controlled.

[0148] The inserts 5, 5’ are positioned in an alignable and adjustable manner, especially in the mold halves 2, 3, with structured mold-taking surfaces 5s, 5s’ in the direction of the injection molding space 10 in the mold 1.

[0149] The inserts 5, 5’ may have alignment marks 5m, 5m’ configured especially as a group of marks, both on the structured mold-taking surfaces 5s, 5s’ and on the backs 5b, 5b’ of the inserts, whereby in particular, the association or correlation between the mold-taking surfaces 5s, 5s’ of the inserts 5, 5’ and the backs 5b, 5b’ of the inserts 5, 5’ can be carried out. The measurement is not necessarily performed within the mold 1.

[0150] In one particularly preferred embodiment (not shown), the backs 5b, 5b’ of the inserts 5, 5’ may be machined to achieve flatness requirements. In this case, the mold-taking surfaces 5s, 5s’ of the inserts 5, 5’ without a structured part can be used. In a special case, the mold-taking surfaces 5s, 5s’ of the inserts 5, 5’ without a structured part may exist regardless of the machining or machinability of the backs 5b, 5b’ of the inserts 5, 5’.

[0151] The mold 1 is filled with injection molding material (not shown) in the filling opening 8, whereby the injection molding material flows into the injection molding space 10 and particularly completely fills the cavity of the injection molding space 10. To enable completely filling the injection molding space 10 of the mold 1 without air bubbles or pores or inclusions, a plurality of degassing passages 9 are formed in the mold 1 in particular.

[0152] In the first mold half 2, the insert 5 is symbolically shown without an inspection window. In order to observe the back surface 5b of the insert 5 in particular using optical means and to enable the inserts 5, 5' to be aligned with each other, a plurality of corresponding passages are formed in the mold 1. In this embodiment, the pressure distributor 7 supports the inserts 5, 5', thereby protecting the inserts 5, 5' from damage due to overload by the injection molding material.

[0153] The overload on the inserts 5, 5' may include thermal overload and mechanical overload, and these overloads can be avoided by arbitrarily clamping the inserts 5, 5' in the mold 1 and, in particular, by supporting them comprehensively.

Explanation of reference numerals

[0154] 1 Mold for injection molding 2 First mold half 3 Second mold half 4 Inspection window 5, 5' Inserts 5s, 5s' Structured mold-taking surfaces of the inserts 5b, 5b' Back surfaces of the inserts 5m, 5m' Alignment marks of the inserts 6 Positioning mechanism 7 Pressure distributor 8 Filling opening 9 Degassing passage 10 Injection molding space E Mold splitting plane

Claims

1. at least, a mould (1) having a first mould half (2) and a second mould half (3), said first mould half (2) and said second mould half (3) defining an injection moulding space (10) in the closed state of said mould (1); at least one insert (5) placed in said injection moulding space (10); An apparatus for injection moulding, in particular for micro injection moulding, comprising: Injection moulding apparatus, characterized in that at least one said insert (5) at least partially comprises a polymer.

2. 2. The apparatus according to claim 1, further comprising at least one further insert (5') arranged in the injection molding space (10), the at least one insert (5) and / or the at least one further insert (5') being alignable in a closed state of the mold (1).

3. 3. The device according to claim 1 or 2, wherein at least one of the inserts (5) and / or at least one of the further inserts (5') each have a molding surface (5s, 5s') with an elastic structure.

4. 4. The apparatus according to claim 1, wherein the molding surface (5s) of at least one of the inserts (5) and the molding surface (5s') of at least one of the further inserts (5') are mutually positionable in a closed state of the mold (1).

5. 5. The apparatus according to claim 1, wherein the structure of the molding surface (5s) of at least one of the inserts (5) and the structure of the molding surface (5s') of at least one further insert (5') are mutually alignable in a closed state of the mold (1).

6. 6. The device according to claim 1, wherein at least one heater is integrated into at least one of the inserts (5), at least one of the further inserts (5') and / or into each of the structures, so that the injection molding space (10), in particular the injection molding material which can be introduced into the injection molding space (10) via the filling opening (8), can be precisely heated by the at least one heater.

7. 7. Apparatus according to claim 1, wherein at least one of the inserts (5) and / or at least one of the further inserts (5') has a plurality of alignment marks (5m, 5m'), in particular on each of the impression surfaces (5s, 5s') and / or on each of the rear surfaces (5b, 5b').

8. 8. Apparatus according to at least one of claims 1 to 7, wherein the first mould half (2) and / or the second mould half (3) have an inspection window (4) by means of which at least one of the inserts (5) and / or at least one of the further inserts (5') are alignable in the closed state of the mould (1) and / or with respect to one another on the basis of a plurality of the alignment marks (5m, 5m').

9. 9. The apparatus according to claim 1, wherein the first mold half (2) and / or the second mold half (3) each have at least one positioning mechanism (6), by means of which at least one insert (5) and / or at least one further insert (5') can be aligned in the closed state of the mold (1) based on a plurality of alignment marks (5m, 5m').

10. 10. The apparatus according to claim 1, wherein the structure of the molding surface (5s) of at least one of the inserts (5) and the structure of the molding surface (5s') of at least one of the further inserts (5') are mutually alignable in a closed state of the mold (1) based on a plurality of alignment marks (5m, 5m') provided on the back surface (5b) of at least one of the inserts (5) and / or the back surface (5b') of at least one of the further inserts (5').

11. An injection molding method, in particular a micro-injection molding method, in which an injection molding space (10) is defined in a closed state of a mold (1) with a first mold half (2) and a second mold half (3), comprising:

2. A method for injection molding, characterized in that at least one insert (5) placed in said injection molding space (10) at least partially comprises a polymer.

12. 12. The method according to claim 11, further comprising aligning the at least one insert (5) and the at least one further insert (5') arranged in the injection-molding space (10) with one another in the closed state of the mold (1), in particular the molding surface (5s) of the at least one insert (5) and / or the molding surface (5s') of the at least one further insert (5').

13. The method according to claim 11 or 12, further comprising aligning at least one of the inserts (5) and / or at least one of the further inserts (5') based on a plurality of alignment marks (5m, 5m') attached to the at least one of the inserts (5) and / or to the at least one of the further inserts (5').

14. 14. The method according to claim 11, further comprising performing an alignment of the at least one insert (5) and / or the at least one further insert (5') based on measurements of an injection-molded part produced by the method according to claim 11.

15. 15. The method according to at least one of claims 11 to 14, wherein alignment is performed by post-treatment of the at least one insert (5) and / or the at least one further insert (5').

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