Precision Decorated Resin Molded Product, Mold, Method for Manufacturing Mold, and Method for Manufacturing Precision Decorated Resin Molded Product

Abstract

The present invention provides a precision decorative resin molding, a metal mold, a metal mold production method, and a method for producing a precision decorative resin molding, in particular, those that have a combination of any of plurality of cutting work regions and a non-cutting work region.　A precision decorative resin molding according to the present invention is produced through injection molding in a metal mold and has at least two regions provided to the surface thereof, said regions each comprising at least two surfaces selected from among a non-cutting work resin surface formed with a mold surface processed by a non-cutting work technique, a first cutting work resin surface formed with a mold surface formed by a first cutting work technique, and a second cutting work resin surface that is formed with a mold surface formed by a second cutting work technique and that is obtained from a condition different from that for the first cutting work resin surface.

Description

Technical Field

[0001] The present invention relates to a precision decorative resin molded article, a mold, a method for manufacturing the mold, and a method for manufacturing a precision decorative resin molded article, and particularly relates to those having either a plurality of cutting regions or non-cutting regions and a manufacturing method thereof.

Background Art

[0002] In recent years, with the development of CAD / CAM technology, the design accuracy of molds has been significantly improved, enabling finer processing. For example, in Patent Document 1, a method for uniformly forming a regular pattern on a metal processing surface has been proposed.

[0003] Further, in Patent Document 2, a design method has been proposed in which the entire processing surface is divided into a combination of the same regular polygon patches or several different-shaped regular polygon patches, and a spiral-shaped one-stroke tool path is set parallel to the sides with a constant cross-feed amount starting from a vertex within the regular polygon patch.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, when forming a molded article using precision decorative resin molding with the actual CAD / CAM technology and using processing with a specific pattern, it often occurs that a monotonous arrangement of patterns results. On the other hand, when drawing a finer design, the design time may become extremely long because more detailed graphics can be drawn. Therefore, as a result of intensive research by the applicants, it has been found that in order to perform more delicate and precise processing on the surface of a mold, not only one type but also a plurality of cutting metal processing methods should be incorporated, and furthermore, a non-cutting metal processing method should also be incorporated, enabling unprecedented precision decorative resin molding.

[0006] An object of the present invention is to provide a precision decorative resin molded product, a mold, a method for manufacturing the mold, and a method for manufacturing the precision decorative resin molded product, particularly those having either a plurality of cutting processing regions or non-cutting processing regions.

Means for Solving the Problems

[0007] The precision decorative resin molded product according to the present invention is a precision decorative resin molded product formed by injection molding in a mold, and its surface has at least two or more regions. The regions are a non-cutting processed resin surface formed by a mold surface processed by non-cutting processing technology, a first cutting processed resin surface formed by a mold surface formed by a first cutting processing technology, and a second cutting processed resin surface formed by a mold surface formed by a second cutting processing technology under conditions different from those of the first cutting processed resin surface, and has at least two or more of these regions.

[0008] The non-cutting processing technology consists of mirror polishing, texturing, photoetching, blasting, laser processing, or a combination thereof.

[0009] In the first cutting processing technology or the second cutting processing technology, the cutting tools are the same, and the pitch of adjacent tool paths when the cutting tools move is different.

[0010] In the first cutting processing technology or the second cutting processing technology, the cutting direction of the cutting tool in the first cutting processing technology is different from the cutting direction of the cutting tool in the second cutting processing technology.

[0011] The first cutting technology or the second cutting technology is characterized in that the cutting tool of the first cutting technology is engraved linearly, and the cutting tool of the second cutting technology is engraved in a curved shape.

[0012] The first cutting technology or the second cutting technology is such that the cutting tool of the first cutting technology is engraved in a curved shape, and the cutting tool of the second cutting technology is also engraved in a curved shape on a curve with different curvatures.

[0013] Either the first cutting technology or the second cutting technology has a cutting direction parallel to the contour line.

[0014] Either the first cutting technology or the second cutting technology has a cutting direction non-parallel to the contour line.

[0015] The precision decorative resin molded product according to the present invention is a precision decorative resin molded product formed by injection molding in a mold. Its surface has at least two or more regions, and after moving a certain distance by a processing tool and changing the direction at the same angle, a regular polygon is formed in a spiral shape with a continuous line to form a plurality of regions.

[0016] The precision decorative resin molded product according to the present invention is a precision decorative resin molded product formed by injection molding in a mold. The surface of a natural object existing in nature is measured in advance as three-dimensional coordinates for the entire surface over an arbitrary area, and the reference plane of its surface is determined in advance. It is converted into emphasized three-dimensional coordinates by multiplying only the numerical values in the height direction from the reference plane in the three-dimensional coordinates by a specific coefficient value, and is formed by a mold that forms a surface region with the emphasized three-dimensional coordinates to form a plurality of regions.

[0017] Characters, figures, or combinations thereof are formed on different resin surfaces.

[0018] The interval of the tool movement pitch when cutting each region of the mold is an interval that becomes a white gloss after molding.

[0019] The interval of the tool movement pitch when cutting each area of the mold is the interval that results in an iridescent luster after molding.

[0020] The regular polygon is a hexagon.

[0021] The natural product is stone.

[0022] The mold for forming a precision decorative resin molded product according to the present invention is a mold for forming a precision decorative resin molded product formed by injection molding in the mold. Its surface has at least two or more areas, and these areas are either the non-cutting resin surface of the mold processed by non-cutting processing technology, the first cutting resin surface of the mold surface formed by the first cutting processing technology, or at least two or more areas of the second cutting resin surface of the mold surface formed by the second cutting processing technology under conditions different from the first cutting resin surface.

[0023] The precision decorative resin molding method according to the present invention is a precision decorative resin molding method formed by injection molding in the mold. Its surface has at least two or more areas, and these areas are either the non-cutting resin surface by the mold surface processed by non-cutting processing technology, the first cutting resin surface formed by the mold surface formed by the first cutting processing technology, or at least two or more areas of the second cutting resin surface formed by the mold surface formed by the second cutting processing technology under conditions different from the first cutting resin surface.

[0024] The manufacturing method of the mold for forming a precision decorative resin molded product according to the present invention is a manufacturing method of the mold for forming a precision decorative resin molded product formed by injection molding in the mold. Its surface has at least two or more areas, and these areas are either the non-cutting resin surface of the mold processed by non-cutting processing technology, the first cutting resin surface of the mold surface formed by the first cutting processing technology, or at least two or more areas of the second cutting resin surface of the mold surface formed by the second cutting processing technology under conditions different from the first cutting resin surface.

Effects of the Invention

[0025] A precision-decorated resin molded product, a mold, a method for manufacturing the mold, and a method for manufacturing the precision-decorated resin molded product according to the present invention, which can provide a novel precision-decorated resin molding by having either a plurality of cutting regions or non-cutting regions.

Brief Description of the Drawings

[0026]

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Embodiments for Carrying Out the Invention

[0027] Next, embodiments of the present invention will be described in detail with reference to the drawings. In all the drawings described below, the same reference numerals are added to the same components, and the description will be omitted as appropriate.

[0028] (First Embodiment) The first embodiment is the configuration of a precision decorative resin molded product. As the precision decorative resin molded product, examples include an audio product exterior cover as a housing of an electrical product, a bumper, a door mirror as an exterior part of an automobile, or a dashboard 4, an instrument panel 6, a center cluster 8, a steering wheel 10, a meter 12, a shift lever 13, etc. as interior parts of an automobile, which are shown in FIG. 1. All or part of these can be configured with a precision decorative resin molded product.

[0029] The resin molded product is molded by injecting and filling resin into a mold having a cavity with a precision decorative resin part. FIG. 2 is an explanatory diagram showing a machining center 22 for machining the mold according to the embodiment. The machining center 22 has a machine tool main body 24 and a control device 26.

[0030] The machine tool body 24 performs a cutting process on the surface of the workpiece 28 to be processed to form a cavity that is a component of the mold. The machine tool body 24 has a spindle 32 that rotatably supports a cutting tool 30 and well-known means for three-dimensionally moving the workpiece 28.

[0031] The cutting tool 30 is preferably an end mill, particularly a ball end mill. The spindle 32 rotates the cutting tool 30 around the Z axis, and the well-known means freely moves the workpiece 28 in the X direction, Y direction, and Z direction.

[0032] The control device 26 is composed of a computer in which a central integrated circuit, an internal storage device, an external storage device, an external interface, and a cutting tool interface are connected by internal wiring, and controls the machine tool body 24 according to NC data. The NC data includes a tool path that is a movement path of the cutting tool 30 defined by the movement amount in the X direction, the movement amount in the Y direction, the movement amount in the Z direction, the rotational speed of the spindle, the feed rate in the X direction, the feed rate in the Y direction, and the movement speed in the Z direction. By moving the workpiece 28 according to the NC data by the control device 26, a cavity and a precision decorative resin handle can be cut on the surface of the workpiece 28.

[0033] Here, the process of creating the NC data is an important process of the present invention. The tool path is designed by a CAD / CAM system, the structure of the precision decorative resin handle is CAD-designed, and as the tool path, by forming a tool path such as a ball end mill, the precision decorative resin handle can be reproduced on the mold surface. Here, the diameter of the ball end mill is preferably from R0.2 to R2, and the interval of the tool path is characterized by being from 25 μm to 500 μm. Further, the shape height from the highest part to the lowest part is 0.05 mm to 0.2 mm, whereby the precision decorative resin can be processed.

[0034] FIG. 3 is a perspective view showing the entire mold 40 according to the present invention. A forming portion formed by non-cutting or cutting technology is provided on the inner surface of the mold 40 that is inside the mold 40 and not shown. The forming portion is cut into a shape in which the mold shape is inverted so as to form the mold shape on the surface of the resin molded product.

[0035] Subsequently, a method for manufacturing the mold 50 and a method for manufacturing the molded product in the first embodiment will be described.

[0036] First, it is determined which part of the resin molded product is to be formed with what design. When the design of the resin molded product is determined, a design of the mold for realizing the design of the resin molded product is performed. In the mold design, depending on the surface state of the molded product at the time of completion, there are cases where cutting processing technology is used and cases where non-cutting processing technology is used. Further, when there are a plurality of surfaces on the surface of one resin molded product, both cutting processing technology and non-cutting processing technology are used for processing on the surface of the mold. Here, in the first embodiment, as shown in FIG. 4A, the mold 50 is composed of a mirror surface portion 52 using non-cutting processing technology and a cutting portion 54 using cutting processing technology.

[0037] The mirror surface portion 52 is polished and mirror-finished with a grindstone, paper polishing, or diamond paste.

[0038] For the cutting portion 54, a tool path 56 is generated by a CAM system for tool path generation using CAD data, which is drawing data of the molded product input in advance. The tool path 56 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 56, cusps 58 are formed parallel to the tool path at both ends thereof.

[0039] On one hand, the machined mold 50 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 50 and cools and solidifies, a resin molded product is formed. As a result, a flat plane corresponding to the mirror surface portion 52 is formed on one side, and on the other hand, a shape in which the portion corresponding to the cutting portion 54 has a concave portion corresponding to the cusp 58 is formed. According to the present embodiment, a molded product having a flat portion and a portion decorated by cutting can be obtained.

[0040] (Second Embodiment) Furthermore, a method for manufacturing the mold 60 and a method for manufacturing the molded product in the second embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 4B, the second embodiment is composed of a dimpled portion 62 using a non-cutting process technology and a cutting portion 64 using a cutting process technology in the mold 60.

[0041] A dimpled pattern 63 is formed in the dimpled portion 62. Specifically, it is transferred to the dimpled portion 62 of the mold 60 with acid-resistant ink.

[0042] Furthermore, when etching is performed, the metal is removed by corrosion where it is not covered by the acid-resistant ink, resulting in a depression.

[0043] Also, a new transfer is made to the remaining portion with acid-resistant ink.

[0044] Subsequently, when etching is performed, the areas not covered by the ink become depressions, but the areas etched in the first etching become even larger depressions.

[0045] Then, a third transfer is made on it with acid-resistant ink.

[0046] Third etching is performed from above. A more complex and deeper depression can be formed. Through the above processing, the dimpled portion 62 is formed. By using this mold 60, a molded product having the shape of the dimpled portion 62 is formed.

[0047] The cutting portion 64 is formed in the same manner as in the first embodiment.

[0048] On the one hand, the processed mold 60 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 60 and cools and solidifies, a resin molded product is formed. As a result, a surface with a texture corresponding to the texture processing part 62 is formed on one side, and on the other hand, a shape in which the part corresponding to the cutting part 64 has a concave part corresponding to the burr 68 is formed.

[0049] According to the present embodiment, a molded product having a portion decorated by texture processing and a portion decorated by cutting can be obtained.

[0050] (Third Embodiment) Furthermore, a method for manufacturing the mold 70 and a method for manufacturing the molded product in the third embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 4C, the third embodiment is composed of a photoetching processing part 72 using a non-cutting processing technique and a cutting part 74 using a cutting processing technique in the mold 70.

[0051] An etching recess pattern 73 is formed in the photoetching processing part 72. Specifically, a pattern film with an etching pattern drawn on the photoetching processing part 72 of the mold 70 is created, the photoetching processing part 72 is subjected to degreasing and cleaning treatment, a photoresist is applied to the photoetching processing part 72, the pattern film is pulled from above and exposed with a semiconductor laser or the like, then development processing is performed, and further etching processing is performed to remove the material in the shape of the pattern. Thereafter, the masking is peeled off to form the photoetching processing part 72.

[0052] The cutting part 74 is formed in the same manner as in the first embodiment.

[0053] On one hand, the processed mold 70 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 70 and cools and solidifies, a resin molded product is formed. As a result, on one side, a photo-etched surface corresponding to the photo-etching processed portion 72 is formed, and on the other side, the portion corresponding to the cutting portion 74 has a shape in which the portion corresponding to the cusp 78 becomes a concave portion.

[0054] According to the present embodiment, a molded product having a portion decorated by photo-etching and a portion decorated by cutting can be obtained.

[0055] (Fourth Embodiment) Furthermore, a method for manufacturing the mold 80 and a method for manufacturing the molded product in the fourth embodiment will be described. In particular, the points different from the first embodiment will be described. As shown in FIG. 4D, the fourth embodiment is composed of a blasting portion 82 using a non-cutting processing technique and a cutting portion 84 using a cutting processing technique in the mold 80.

[0056] In the blasting portion 82, a blasting concave pattern 83 is formed. Specifically, a granular abrasive material of an appropriate size for processing the blasting portion 82 of the mold 80 is struck against the metal surface at high speed to remove the surface scale (for example, iron oxide), rust, and other foreign substances, or to perform surface conditioning of the metal surface. As the abrasive material, mainly silica sand, silicon carbide, alumina, etc. are used. The blasting portion 82 is formed by these abrasive materials.

[0057] The cutting portion 84 is formed in the same manner as in the first embodiment.

[0058] On one hand, the processed mold 80 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 80 and cools and solidifies, a resin molded product is formed. As a result, on one side, a blasted surface corresponding to the blasting portion 82 is formed, and on the other side, the portion corresponding to the cutting portion 84 has a shape in which the portion corresponding to the cusp 88 becomes a concave portion.

[0059] According to this embodiment, a molded product having a portion decorated by blasting and a portion decorated by cutting can be obtained.

[0060] (Fifth Embodiment) Furthermore, a method for manufacturing the mold 90 and a method for manufacturing the molded product in the fifth embodiment will be described. In particular, the differences from the first embodiment will be described. As shown in FIG. 4E, the fifth embodiment is composed of a laser processing section 92 using a non-cutting processing technique and a cutting section 94 using a cutting processing technique in the mold 90.

[0061] A laser recess pattern 93 is formed in the laser processing section 92. Specifically, the surface of the mold 90 is processed by moving and irradiating the laser processing section 92 of the mold 90 with an ultrashort pulse laser based on design data. At this time, by using a picosecond or femtosecond laser or one that requires higher precision without using a continuous laser or a nanosecond laser, the generation of burrs and thermal damage can be prevented.

[0062] The cutting section 94 is formed in the same manner as in the first embodiment.

[0063] On the other hand, the processed mold 90 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 90 and cooled and solidified, a resin molded product is formed. As a result, a laser-processed surface corresponding to the laser processing section 92 is formed on one side, and on the other side, a shape in which the portion corresponding to the cusp 98 becomes a recess is formed in the portion corresponding to the cutting section 94.

[0064] According to this embodiment, a molded product having a portion decorated by laser processing and a portion decorated by cutting can be obtained.

[0065] (Sixth Embodiment) Next, a method for manufacturing the mold 100 and a method for manufacturing a molded product in the sixth embodiment will be described. In particular, differences from the first embodiment will be described. As shown in Fig. 4F, the sixth embodiment includes an electric discharge machining part 102 that uses non-cutting machining technology and a cutting part 104 that uses cutting machining technology in the mold 100.

[0066] In the electric discharge machining part 102, an electric discharge machining pattern 103 is formed. Specifically, the electric discharge machining part 102 of the mold 100 is moved based on design data by an electric discharge engraving machine or a wire electric discharge machining machine to machine the mold surface. At this time, if it is a wire electric discharge machining machine, it can be controlled by NC data.

[0067] Through these processes, the electric discharge machining part 102 is formed.

[0068] The cutting part 104 is formed in the same manner as in the first embodiment.

[0069] On the other hand, the machined mold 100 is incorporated into an injection molding machine, and when the molding resin is injected into the cavity formed by the mold 100 and cooled and solidified, a resin molded product is formed. As a result, on one hand, a surface machined by electric discharge machining corresponding to the electric discharge machining part 102 is formed, and on the other hand, a shape in which the part corresponding to the cutting part 104 has a concave part corresponding to the cusp 108 is formed.

[0070] According to the present embodiment, a molded product having a portion decorated by electric discharge machining and a portion decorated by cutting machining can be obtained.

[0071] (Seventh Embodiment) Next, a method for manufacturing the mold 110 and a method for manufacturing a molded product in the seventh embodiment of the precision decorated resin molded product according to the present invention will be described. The seventh embodiment is different only in the machining method of the cutting part 114 from the sixth embodiment. The cutting part 114 generates a tool path 116 from CAD data using a CAM system (Fig. 4G). The tool path 116 is set so that the ball end mill moves in the designed direction. Here, up to the sixth embodiment, adjacent tool paths are designed such that the moving direction of the tool is opposite. By reversing the moving direction, the return process of the tool can also be utilized as processing time, thus having the effect of shortening the cutting time. On the other hand, in the seventh embodiment, all adjacent tool paths are cut in the same direction. By machining in the same direction for all cutting directions, the cutting marks and the like have the same tendency, so the finish is uniform, the appearance is uniform, and it becomes a desirable trace without the appearance being rough. Therefore, the molded products molded by the mold created by this method also have the effect of having a uniform finish.

[0072] (Eighth Embodiment) Furthermore, the manufacturing method of the mold 120 and the manufacturing method of the molded product in the eighth embodiment will be described. In particular, the points different from the first embodiment will be described. As shown in Fig. 5A, the sixth embodiment is composed of a first pitch cutting part 122 that uses cutting processing technology and a second pitch cutting part 124 that also uses cutting processing technology in the mold 120.

[0073] The first pitch cutting part 122 generates a tool path 126 from CAD data using a CAM system. The tool path 126 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 126, cusps 128 are formed in parallel with the tool path at both ends thereof, separated by a first pitch derived from the cutting width of the ball end mill.

[0074] On the other hand, the second pitch cutting part 124 generates a tool path 130 from CAD data using a CAM system. The tool path 130 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 130, cusps 132 are formed in parallel with the tool path at both ends thereof, separated by a second pitch narrower than the first pitch and derived from the cutting width of the ball end mill.

[0075] Subsequently, the processed mold 120 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 120 and cools and solidifies, a resin molded product is formed. As a result, on one side, a portion corresponding to the first pitch cutting portion 122 forms a shape in which a portion corresponding to the cusp 128 becomes a concave portion, and on the other side, a portion corresponding to the second pitch cutting portion 124 forms a shape in which a portion corresponding to the cusp 132 becomes a concave portion.

[0076] According to the present embodiment, a molded product having a portion decorated by cutting with different pitches can be obtained.

[0077] (Ninth Embodiment) Furthermore, a method for manufacturing the mold 140 and a method for manufacturing the molded product in the ninth embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5B, the ninth embodiment is composed of a first direction cutting portion 142 that uses a cutting technique in the mold 140 and a second direction cutting portion 144 that also uses a cutting technique.

[0078] The first direction cutting portion 142 generates a tool path 146 using a CAM system from CAD data. The tool path 146 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 146, a cusp 148 is formed in parallel with the tool path at both ends thereof with a first pitch derived from the cutting width of the ball end mill.

[0079] On the other hand, the second direction cutting portion 144 generates a tool path 150 that is 90 degrees different from the tool path 146 in the cutting direction using a CAM system from CAD data. The tool path 150 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 150, a cusp 152 is formed in parallel with the tool path at both ends thereof with a first pitch derived from the cutting width of the ball end mill.

[0080] Subsequently, the processed mold 140 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 140 and cools and solidifies, a resin molded product is formed. As a result, on one side, a portion corresponding to the first-direction cutting portion 142 forms a shape in which a portion corresponding to the cusp 148 is a recess, and on the other side, a portion corresponding to the second-direction cutting portion 144 forms a shape in which a portion corresponding to the cusp 152 is a recess. According to the present embodiment, a molded product having a portion decorated by cutting in different directions can be obtained.

[0081] (Tenth Embodiment) Furthermore, a method for manufacturing the mold 160 and a method for manufacturing the molded product in the tenth embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5C, the tenth embodiment is composed of a linear cutting portion 162 that uses a cutting process technology in the mold 160 and a curved cutting portion 164 that also uses a cutting process technology.

[0082] For the linear cutting portion 162, similar to the first and second embodiments, a tool path 166 is generated from CAD data using a CAM system. The tool path 166 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 166, a cusp 168 is formed in parallel to the tool path at intervals of a first pitch derived from the cutting width of the ball end mill at both ends thereof.

[0083] On the other hand, for the curved cutting portion 164, a curved tool path 170 is generated from CAD data using a CAM system. The tool path 170 is set so that the ball end mill moves in a curved shape in the designed direction. When the ball end mill cuts the mold along the tool path 170, a curved cusp 172 is formed in parallel to the tool path in a curved shape at intervals of a first pitch derived from the cutting width of the ball end mill at both ends thereof.

[0084] Subsequently, the processed mold 160 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 160 and cooled and solidified, a resin molded product is formed. As a result, a shape is formed in which the portion corresponding to the straight cutting portion 162 on one side has a concave portion corresponding to the cusp 168, and on the other hand, the portion corresponding to the curved cutting portion 164 has a concave portion corresponding to the cusp 172.

[0085] According to the present embodiment, a molded product having a portion decorated by curved cutting and straight cutting can be obtained.

[0086] (Eleventh Embodiment) Furthermore, a method for manufacturing the mold 180 and a method for manufacturing a molded product in the eleventh embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5D, the eleventh embodiment is composed of a curved cutting portion 182 having a first curvature using a cutting technique in the mold 180 and a curved cutting portion 184 having a second curvature using the same cutting technique.

[0087] The first curvature curved cutting portion 182 generates a tool path 186 using a CAM system from CAD data, similar to the ninth embodiment. The tool path 186 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 186, a first curvature cusp 188 is formed in parallel with the tool path at both ends thereof with a first pitch derived from the cutting width of the ball end mill.

[0088] On the other hand, for the curved cutting portion 184 having the second curvature, a second curvature curved tool path 190 is generated using a CAM system from CAD data. The tool path 190 is set so that the ball end mill moves in a curved shape in the designed direction. When the ball end mill cuts the mold along the tool path 190, a second curvature curved cusp 192 is formed in parallel with the tool path in a second curvature curved shape at both ends thereof with a first pitch derived from the cutting width of the ball end mill.

[0089] Subsequently, the processed mold 180 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 180 and cooled and solidified, a resin molded product is formed. As a result, on one side, a portion corresponding to the first curvature curve cutting portion 182 forms a shape in which a portion corresponding to the first curvature cusp 188 is a concave portion, and on the other side, a portion corresponding to the second curvature curve cutting portion 184 forms a shape in which a portion corresponding to the second curvature cusp 192 is a concave portion.

[0090] According to the present embodiment, a molded product having a portion decorated by the first curvature curve cutting and the second curvature cutting can be obtained.

[0091] (Twelfth Embodiment) Furthermore, a method for manufacturing the mold 200 and a method for manufacturing the molded product in the twelfth embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5E, the twelfth embodiment is composed of a linear cutting portion 202 that uses a cutting technique and a contour parallel cutting portion 204 that also uses a cutting technique in the mold 200.

[0092] The linear cutting portion 202 generates a tool path 206 using a CAM system from CAD data, similar to the first and second embodiments. The tool path 206 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 206, a cusp 208 is formed parallel to the tool path at both ends thereof with a first pitch derived from the cutting width of the ball end mill.

[0093] On the other hand, the contour parallel cutting portion 204 generates tool paths 216, 218 parallel to the contours 210, 212, 214 using a CAM system from CAD data. The tool paths 216, 218 are set so that the ball end mill moves parallel to the contours in the designed direction. When the ball end mill cuts the mold along the tool paths 216, 218, a cusp that is also the contours 210, 212, 214 is formed parallel to the tool paths at both ends thereof with a first pitch derived from the cutting width of the ball end mill.

[0094] Subsequently, the processed mold 200 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 200 and cools and solidifies, a resin molded product is formed. As a result, a shape is formed in which the portion corresponding to the linear cutting portion 202 on one side has a concave portion corresponding to the cusp 208, and on the other hand, the portion corresponding to the contour parallel cutting portion 204 has a concave portion corresponding to the portion parallel to the contour.

[0095] According to the present embodiment, a molded product having a portion decorated by contour parallel cutting and linear cutting can be obtained.

[0096] (The thirteenth embodiment) Furthermore, a method for manufacturing the mold 220 and a method for manufacturing the molded product in the thirteenth embodiment will be described. In particular, differences from the twelfth embodiment will be described. As shown in FIG. 5F, the thirteenth embodiment is composed of a linear cutting portion 222 that uses a cutting technique in the mold 220 and a contour non-parallel cutting portion 224 that also uses a cutting technique. Since the linear cutting portion 222 is the same as that in the twelfth embodiment, it will not be particularly described here.

[0097] Here, for the contour non-parallel cutting portion 224, tool paths 236, 238, 240, 242, 244, 246, 248, 250 that are non-parallel to the contours 230, 232, 234 are generated using a CAM system from CAD data. The tool paths 236, 240, 244, 248 are cut in a direction perpendicular to the contour from the center of the contour toward the outer edge direction, and the tool paths 238, 242, 246, 250 are cut from the outer edge direction toward the center of the contour. When a ball end mill cuts the mold along the tool paths 236, 240, 244, 248, cusps are formed at both ends at a first pitch in a direction perpendicular to the contour and the tool path due to the cutting width of the ball end mill.

[0098] Subsequently, the processed mold 220 is incorporated into an injection molding machine. When the molding resin is injected into the cavity formed by the mold 220 and cools and solidifies, a resin molded product is formed. As a result, a shape is formed in which the portion corresponding to the linear cutting portion 222 has a recessed portion corresponding to the cusp 228, and on the other hand, in the portion corresponding to the contour non-parallel cutting portion 224, a recessed portion is formed in the portion perpendicular to the contour.

[0099] According to the present embodiment, a molded product having a portion decorated by contour non-parallel cutting and linear cutting can be obtained.

[0100] (Fourteenth Embodiment) Furthermore, a method for manufacturing the mold 260 and a method for manufacturing a molded product in the fourteenth embodiment will be described. In particular, the points different from the first embodiment will be described. As shown in FIG. 5G, in the fourteenth embodiment, the mold 260 is provided with concentric circular boundary lines 262, 264, 266, 268, 270, 272, 274, 276 and axial radius boundary lines 261, 263, 265 for a circular pattern, and adjacent regions are configured to be processed by different processing methods. As one method, the entire circumference can be processed by changing the cutting direction by 90 degrees in adjacent regions.

[0101] The first direction cutting portion 278 generates a first tool path in the circumferential direction from CAD data using a CAM system. The first tool path is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path, a cusp is formed in parallel with the tool path at both ends thereof with a first pitch derived from the cutting width of the ball end mill.

[0102] On the other hand, the second-direction cutting part 280 generates a second tool path whose cutting direction is 90 degrees different from that of the first tool path using a CAM system from CAD data. The second tool path is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the second tool path, cusps are formed in parallel to the tool path with a first pitch separated at both ends due to the cutting width of the ball end mill. This process is performed across the front surface of the decorative pattern.

[0103] Subsequently, the processed mold 260 is incorporated into an injection molding machine, and when the molding resin is injected into the cavity formed by the mold 260 and cooled and solidified, a resin molded product is formed. As a result, on one hand, a shape is formed in which the part corresponding to the first-direction cutting part has a concave part corresponding to the cusp, and on the other hand, a shape is formed in which the part corresponding to the second-direction cutting part has a concave part corresponding to the cusp.

[0104] According to the present embodiment, a molded product having a decorated part by cutting processes in different directions can be obtained.

[0105] (Fifteenth Embodiment) Furthermore, a method for manufacturing the mold 290 and a method for manufacturing a molded product in the fifteenth embodiment will be described. In particular, differences from the first embodiment will be described. In the fifteenth embodiment, as shown in FIG. 6, in the mold 290, by machining a cutting tool adjacent to the mold 290 a plurality of times in a specific direction, cusps 296 parallel to the tool paths 292, 294 are formed. Here, when the interval l between the cusps 296 is set to be from 100 nm to 600 nm, adjacent reflected lights interfere with each other by reflection by adjacent cutting traces by the cutting tool, resulting in iridescent reflection. This can occur in both the mold and the molded product. Also, when the surface roughness, which is the height of the cusp, is set to be from 0.00 to 0.20 μm, it becomes specular reflected light without becoming iridescent, when the surface roughness is from 0.20 to 0.40 μm, the formed surface by the cusp becomes iridescent, and when the surface roughness is 0.40 μm or more, it becomes white gloss.

[0106] (Sixteenth Embodiment) Next, in the sixteenth embodiment, a method of drawing a natural object on the mold surface for decoration will be described. Here, as the natural object, the ripples on the water surface of a shallow pool are adopted. A photograph of the ripple 300 is shown in Fig. 7A.

[0107] The first step is to photograph the ripple, which is a natural object, and convert it into a grayscale image. For example, here it is assumed to be saved as a jpeg image. The jpeg image data is composed of a segment and image data for each frame, and the grayscale image records the gradation for each pixel.

[0108] The second step is to convert the jpeg image data into intermediate data. Specifically, among the image data, the X and Y coordinate data are used as position coordinates. On the other hand, it is a step of converting the gradation data into Z coordinate data. When it is the lightest gradation, the Z coordinate is set to the maximum value, and when it is the darkest gradation, the Z coordinate is set to the maximum value. By setting in this way, the shading can be expressed by the mold. The three-dimensional data (x, y, z) 302 thus obtained is shown in Fig. 7B.

[0109] In the third step, further, in order to add undulations to the water surface, the undulation data 304 is prepared and the visualized one is shown in Fig. 7C. As the undulation data 304, data of the same area as the three-dimensional data 302 in (x, y, z) coordinates is generated in advance.

[0110] The fourth step is the combined data 306 obtained by combining the ripple three-dimensional data (x, y, z) 302 and the undulation data (x, y, z) 304. By constructing a tool path from this combined data (x, y, z) 306, the mold data for the ripple can be constructed.

[0111] In addition, as natural objects other than the water surface, as shown in Figs. 8A to 8E, rocks 308 such as granite, plants 310 such as tree leaves, leather 312 such as napped leather, wood grain 314, Japanese paper 316, etc. can be used.

[0112] (Example) (Example 1) Example 1 will be described with reference to FIG. 9 showing an overall view and FIG. 10 showing an enlarged view of the boundary at 120 times magnification. Example 1 shows a precision decorative resin molded product 400 made of ABS resin according to the present invention. On the surface of the precision decorative resin molded product 400, there are tool path marks 402 and 404 in two different directions. That is, the precision decorative resin molded product 400 is a precision decorative resin molded product molded by a mold having a first-direction cutting part and a second-direction cutting part. By implementing the present invention, a precision decorative resin molded product that reproduces carbon resin can be produced. By using ABS resin, the gloss of the precision decorative resin molded product 400 is remarkable.

[0113] (Example 2) Example 2 will be described with reference to FIG. 11 showing an overall view and FIG. 12 showing an enlarged view of the boundary at 120 times magnification. Example 2 shows a precision decorative resin molded product 410 made of polypropylene (PP) resin according to the present invention. On the surface of the precision decorative resin molded product 410, there are tool path marks 412 and 414 in two different directions. That is, the precision decorative resin molded product 410 is a precision decorative resin molded product molded by a mold having a first-direction cutting part and a second-direction cutting part. By implementing the present invention, a precision decorative resin molded product that reproduces carbon resin can be produced. By using PP resin, the precision decorative resin molded product 410 has a feature of having a stable gloss.

[0114] (Example 3) Example 3 will be described with reference to FIG. 13 showing an overall view and FIG. 14 showing an enlarged view of the boundary at 120 times magnification. Example 3 shows a precision decorative resin molded product 420 according to the present invention. On the surface of the precision decorative resin molded product 420, a carbon-like design with tool path marks 422 and 424 in two different directions, a leaf-shaped design 426 with parallel vein-like cutting marks thereon, and a mirror-like character design 428 are displayed. That is, the precision decorative resin molded product 420 is a precision decorative resin molded product molded by a mold having a first-direction cutting part, a second-direction cutting part, and a non-cutting part. By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0115] (Example 4) Example 4 of the present invention will be described with reference to FIG. 15 showing an overall view and FIG. 16 showing an enlarged view of the boundary at 120 times magnification. Example 4 shows a precision decorative resin molded product 430 according to the present invention. The precision decorative resin molded product 430 has a carbon-like design with tool path marks 432 and 434 in two different directions on the surface, a design 436 in which the shape is an automobile silhouette and slanted hairlines are arranged at intervals of 100 nm to 600 nm to realize an iridescent color, a design 438 in which the actual part of a cherry is formed with concentric caps by cutting to realize an iridescent color, a character design 440 in which hairlines are engraved on the surface to realize an iridescent color, and a design 442 in which the shape of Yamagata Prefecture is shown in silhouette. Here, a hairline is a short linear mark composed of tool path marks. It refers to a state in which a plurality of these linear marks are engraved. That is, the precision decorative resin molded product 420 is a precision decorative resin molded product molded by a mold including a first-direction cutting part, a second-direction cutting part, and a non-cutting part. By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0116] (Example 5) Example 5 of the present invention will be described with reference to FIG. 17 showing an overall view and FIG. 18 showing an enlarged view of the boundary at 120 times magnification. Example 5 shows a precision decorative resin molded product 450 according to the present invention. The precision decorative resin molded product 450 has a check-like design with tool path marks 452 and 454 in two different directions on the surface. The tool path marks 452 and 454 are cutting marks arranged at intervals of 100 nm to 600 nm respectively, and when light is irradiated, the reflected light shines in an iridescent color depending on the reflection angle. The tool path marks 452 and 454 are arranged alternately in a row in the horizontal direction in FIG. 17, and in the vertical direction in FIG. 17, they do not form a single row, and the upper and lower adjacent squares are always shifted to the left and right and in contact with each other.

[0117] That is, the precision decorative resin molded product 450 is a precision decorative resin molded product molded by a mold including a first-direction cutting part and a second-direction cutting part. By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0118] (Example 6) Example 6 of the present invention will be described with reference to FIG. 19 showing an overall view and FIG. 20 showing an enlarged view of the boundary at 120 times magnification. Example 6 shows a precision decorative resin molded product 460 according to the present invention. On the surface of the precision decorative resin molded product 460, a checkered design is formed in which tool path marks 462, 464, 466, and 468 in two different directions are present. The tool path marks 462, 464, 466, and 468 are cutting marks arranged at intervals of 100 nm to 600 nm, respectively, and when irradiated with light, the reflected light shines in a rainbow color depending on the reflection angle. The tool path marks 462, 464, 466, and 468 are arranged alternately in a row in an oblique direction in FIG. 19 and are also arranged alternately in a row in an intersecting oblique direction and are in contact with each other.

[0119] That is, the precision decorative resin molded product 460 is a precision decorative resin molded product molded by a mold including a first-direction cutting part and a second-direction cutting part. By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0120] (Example 7) Example 7 of the present invention will be described with reference to FIG. 21 showing an overall view and FIG. 22 showing an enlarged view of the boundary at 120 times magnification. Example 7 shows a precision decorative resin molded product 470 according to the present invention. On the surface of the precision decorative resin molded product 470, a plurality of S-shaped patterns 472 are arranged continuously in the horizontal direction, a plurality of reverse S-shaped patterns 474 are arranged symmetrically at both ends in the horizontal direction, and further, a plurality of reverse S-shaped patterns 474 are arranged continuously in the horizontal direction and symmetrically, and adjacent to this, a plurality of S-shaped patterns 472 are arranged continuously in the horizontal direction and arranged repeatedly. Here, on the surfaces of the S-shaped pattern 472 and the reverse S-shaped pattern 474, a plurality of S-shaped and reverse S-shaped tool path marks exist, respectively. These tool path marks are cutting marks arranged at intervals of 100 nm to 600 nm, respectively, and when irradiated with light, the reflected light shines in a rainbow color depending on the reflection angle.

[0121] That is, the precision decorative resin molded product 470 is a precision decorative resin molded product molded with a mold having a plurality of cutting portions with curved portions. By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0122] (Example 8) The hexagon-shaped template scanning line processing of Example 8 according to the present invention will be described with reference to FIG. 23 showing an overall view, FIG. 24 showing a 120-fold magnified view of the boundary, and FIG. 25 showing a block diagram. Example 8 shows a precision decorative resin molded product 480 according to the present invention. The precision decorative resin molded product 480 is a molded product covered with a shape engraved so as to cover the surface with a regular hexagonal pyramid using six regular triangles 482, 484, 486, 488, 490, 492. The feature of this example is that, as shown in FIG. 24, the tool path of the cutting tool during mold manufacturing is configured such that, regardless of the shape of the regular hexagon, in this photograph, if a tool path mark 494 in the rightward direction from the front left is provided, the next tool path mark 496 is moved in the leftward direction from the front right, and adjacent tool paths are straight across the entire figure, and adjacent tool path marks are parallel. This processing method is called scanning line processing, and since the moving time of the tool can be utilized for the round trip of going and returning, the processing time is reduced by half compared to that in one direction. Also, the intervals between the respective tool path marks are cutting marks arranged at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in a rainbow color depending on the reflection angle. In particular, in this example, a rainbow is likely to occur.

[0123] Also, when reflecting, the triangles shine alternately, and the upper and lower triangles shine, and as shown in FIG. 23, it is characterized by shining in a diamond shape.

[0124] That is, the precision decorative resin molded product 480 is a precision decorative resin molded product molded with a mold having a plurality of cutting portions with curved portions. By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0125] As the mold processing steps also used in Example 8, as shown in Fig. 25, as the first-stage processing, contour machining for moving the tool path along the contour line of the hexagonal pyramid part is performed as roughing (A2).

[0126] As the second-stage processing, scanning line machining is performed as semi-finishing (A4).

[0127] As the third-stage processing, scanning line machining is performed as finishing (A6).

[0128] (Example 9) The overall view of the hexagonal-patterned template spiral machining of Example 9 according to the present invention will be described with reference to Fig. 26 showing the overall view, Fig. 27 showing an enlarged view of the boundary at 120 times, and Fig. 28 showing a block diagram. Example 9 shows a precision decorative resin molded product 500 according to the present invention. The precision decorative resin molded product 500 is a molded product covered with a shape engraved so as to cover the surface with a regular hexagonal pyramid using six equilateral triangles 502, 504, 506, 508, 510, 512. The feature of this example is that, as shown in Fig. 27, when the tool path of the cutting tool during mold manufacturing is provided along the contour line of the regular hexagon, specifically, a tool path mark 514 in the direction from the upper right to the lower right in the front view, that is, by changing the direction at the same angle after moving a certain distance, a regular polygon is formed continuously in a spiral shape by a continuous line. Specifically, the next tool path mark 516 is configured to move from the center right to the lower left in the front view, and adjacent tool path marks form a hexagon in a spiral vortex shape over the entire figure, and adjacent tool path marks are configured to be parallel. This processing method is called scanning line machining, and since the moving time of the tool can be utilized for both the forward and return trips, the processing time is reduced by half compared to that in one direction. Also, the intervals between the respective tool path marks are cutting marks arranged at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in a rainbow color depending on the reflection angle. Particularly in this example, a rainbow is likely to occur.

[0129] Also, when reflecting, the triangles shine alternately, but the upper and lower triangles do not shine. For example, as shown in Fig. 26, it is characteristic that they shine in any triangular shape.

[0130] That is, the precision decorative resin molded product 500 is a precision decorative resin molded product molded by a mold having a plurality of cutting portions with curved portions. By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0131] As a mold processing step also used in Example 9, as shown in FIG. 28, as the first-stage processing, contour machining for moving the tool path along the contour of the hexagonal hammer portion is performed as roughing (B2).

[0132] As the second-stage processing, scanning line machining is performed as semi-finishing (B4).

[0133] As the third-stage processing, 3D equal pitch machining as finishing is performed (B6).

[0134] (Example 10) Regarding Example 10 of the stone pattern molded product according to the present invention, FIG. 29 showing an overall view, FIG. 30 showing an enlarged view of the boundary at 120 times magnification, and FIGS. 31 to 34 will be used to explain the mold manufacturing method. Example 10 shows the precision decorative resin molded product 520 according to the present invention. The precision decorative resin molded product 520 is a molded product obtained by scanning a natural object to manufacture a mold and molding based on the mold.

[0135] The method for manufacturing a mold for molding the precision decorative resin molded product 520 will be described as follows. First, an example of the natural object to be scanned in the first step is the granite 308 shown in FIG. 8A.

[0136] In the second step, 3D scanning is performed on the selected granite to obtain the position information and height information of the surface irregularities. The actually obtained data is shown in FIG. 32. The y coordinate is fixed and the x and z coordinates are displayed. FIG. 31 shows an image of this data for all y coordinates.

[0137] In the third step, the Z coordinate data of the 3D scan data obtained in the second step is converted by a specific proportional coefficient. The data obtained by the conversion is shown in FIG. 33.

[0138] In the fourth process, a tool path is created based on the data before processing obtained in the second process, and the die surface is machined (Fig. 34C2).

[0139] In the fifth process, a blasting process is performed on the die machined in the fourth process (Fig. 34C4).

[0140] In the sixth process, the die surface is re-machined based on the data machined in the Z direction in the third process for the blasted die (Fig. 34C6). For this reason, the portion indicated by 522 in Fig. 33 is further cut. Also, a part of 522 in a part of Fig. 29 is partially mirror-finished.

[0141] In the seventh process, injection molding is performed using the die completed in the sixth process. Thus, the precision decorative resin molded product 520 shown in Example 10 according to the present invention is formed.

[0142] By implementing the present invention, precision decorative resin molded products with various designs can be produced.

[0143] (Example 11) Example 11 according to the present invention will be described with reference to Fig. 35 showing an overall view. Example 11 shows a precision decorative resin molded product 530 according to the present invention. The precision decorative resin molded product 530 includes concentric circular boundary lines 538, 540, 542, 544, 546, 548, 550 and axial radius boundary lines 532, 534, 536 for a circular pattern, and adjacent regions are configured to be machined by different machining methods. As one method, the entire circumference can be machined by changing the cutting direction by 90 degrees in adjacent regions. Each of the regions has tool path marks, which are cutting marks arranged at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in a rainbow color depending on the reflection angle. The tool path marks are arranged alternately in a row in the horizontal direction in Fig. 35, and in the vertical direction in Fig. 35, the adjacent squares above and below do not form a single row and are always shifted left and right and in contact with each other.

Explanation of Signs

[0144] 2 Interior parts 4 Dashboard 6 Instrument Panel 8 Center Cluster 10 Steering Wheel 12 Meter 13 Shift Lever 22 Machining Center 24 Machine Tool Body 26 Control Device 28 Workpiece 30 Cutting Tool 32 Spindle 40 Mold 50 Mold 52 Mirror Surface Part 54 Cutting Part 56 Tool Path 58 Cusp 60 Mold 62 Textured Processing Part 63 Wrinkled Pattern 64 Cutting Part 68 Cusp 70 Mold 72 Photoetching Processing Part 73 Etched Concave Pattern 74 Cutting Part 78 Cusp 80 Mold 82 Blasting Processing Part 83 Blasted Concave Pattern 84 Cutting Part 88 Cusp 90 Mold 92 Laser Processing Part 93 Laser Etched Concave Pattern 94 Cutting Part 98 Cusp 100 Mold 102 Electrical Discharge Machining Part 103 Electrical Discharge Machining Pattern 104 Cutting Part 108 Cusp 110 Mold 114 Cutting Part 116 Tool Path 120 Mold 122 First Pitch Cutting Part 124 Second pitch cutting part 126 Tool path 128 Cusp 130 Tool path 132 Cusp 140 Mold 142 First direction cutting part 144 Second direction cutting part 146 Tool path 148 Cusp 150 Tool path 152 Cusp 160 Mold 162 Linear cutting part 164 Curve cutting part 166 Tool path 168 Cusp 170 Tool path 172 Cusp 180 Mold 182 First curvature curve cutting part 184 Second curvature curve cutting part 186 Tool path 188 First curvature cusp 188 Cusp 190 Tool path 192 Second curvature cusp 200 Mold 202 Linear cutting part 204 Contour parallel cutting part 206 Tool path 208 Cusp 210,212,214 Contour 216,218 Tool path 220 Mold 222 Linear cutting part 224 Contour non - parallel cutting part 228 Cusp 230,232,234 Contour 236,238,240、242,244,246,248,250 Tool path 260 Mold 262,264,266,268,270,272,274,276 Circular boundary line 261, 263, 265 Radius boundary line 278 First-direction cutting part 280 Second-direction cutting part 290 Mold 292, 294 Tool path 296 Cusp 300 Ripple 302 3D data 304 Waviness data (x, y, z) 306 Combination data (x, y, z) 308 Rocks such as granite 310 Plants such as leaves 312 Leather such as suede 314 Grain 316 Japanese paper 400 Precision-decorated resin molded product 402, 404 Tool path marks 410 Precision-decorated resin molded product 412, 414 Tool path marks 420 Precision-decorated resin molded product 422, 424 Tool path marks 426 Leaf design 428 Character design 420 Precision-decorated resin molded product 450 Precision-decorated resin molded product 430 Precision-decorated resin molded product 432, 434 Tool path marks 436 Design 438 Design 440 Character design 442 Design 452, 454 Tool path marks 450 Precision-decorated resin molded product 460 Precision-decorated resin molded product 462, 464, 466 and 468 Tool path marks 470 Precision-decorated resin molded product 472 S-shaped pattern 474 Reverse S-shaped pattern 480 Precision-decorated resin molded product 482, 484, 486, 488, 490, 492 Equilateral triangle 494 tool path marks 496 tool path marks 500 Precision Decorated Resin Molded Product 502, 504, 506, 508, 510, 512 Equilateral triangle 514 tool path marks 516 tool path marks 520 Precision Decorated Resin Molded Product 520 Precision Decorated Resin Molded Product 522 Mirror finished part 530 Precision Decorated Resin Molded Product 538, 540, 542, 544, 546, 548, 550 Circular boundary line 532, 534, 536 Radius boundary line

Claims

1. In a precision decorative resin molded product formed by injection molding in a mold, its surface has at least two or more regions, the regions are a non-cutting processed resin surface by a mold surface processed by a non-cutting processing technology, a first cutting processed resin surface formed by a mold surface formed by a first cutting processing technology, a precision decorative resin molded product having at least two or more regions of a second cutting processed resin surface formed by a mold surface formed by a second cutting processing technology which is a condition different from that of the first cutting processed resin surface, the precision decorative resin molded product is characterized in that in the first cutting processing technology or the second cutting processing technology, the cutting direction of the cutting tool of the first cutting processing technology is different from the cutting direction of the cutting tool of the second cutting processing technology.

2. The precision decorative resin molded product according to claim 1, wherein the non-cutting processing technology consists of mirror polishing, embossing, photoetching, blasting, laser processing, electrical discharge machining, or a combination thereof.

3. The precision decorative resin molded product according to claim 1 or 2, wherein in the first cutting processing technology or the second cutting processing technology, the cutting tools are the same, and the pitch of adjacent tool paths when the cutting tool moves is different.

4. The precision decorative resin molded product according to any one of claims 1 to 3, wherein in the first cutting processing technology or the second cutting processing technology, the cutting tool of the first cutting processing technology is engraved linearly, and the cutting tool of the second cutting processing technology is engraved curvilinearly.

5. The precision decorative resin molded product according to any one of claims 1 to 3, wherein in the first cutting processing technology or the second cutting processing technology, the cutting tool of the first cutting processing technology is engraved curvilinearly, and the cutting tool of the second cutting processing technology is also engraved curvilinearly with a different curvature.

6. The precision decorative resin molded product according to any one of claims 1 to 3, wherein either the first cutting technology or the second cutting technology is characterized in that the cutting direction is parallel to the contour line.

7. The precision decorative resin molded product according to any one of claims 1 to 3, wherein either the first cutting technology or the second cutting technology is characterized in that the cutting direction is non-parallel to the contour line.

8. In a precision decorative resin molded product formed by injection molding in a mold, its surface has at least two or more regions, A precision decorative resin molded product that forms a plurality of regions by forming a regular polygon in a spiral shape with a continuous line by changing the direction at the same angle after moving a certain distance by a processing tool.

9. In a precision decorative resin molded product formed by injection molding in a mold, The surface of a naturally occurring natural object is measured in advance as three-dimensional coordinates for the entire surface over an arbitrary area, a reference plane of the surface is determined in advance, and only the numerical values in the height direction from the reference plane among the three-dimensional coordinates are multiplied by a specific coefficient value to be converted into emphasized three-dimensional coordinates, and a precision decorative resin molded product formed by a mold that forms a surface area with the emphasized three-dimensional coordinates and forms a plurality of regions.

10. The precision decorative resin molded product according to any one of claims 1 to 7, characterized in that characters, figures, or a combination thereof are formed on different resin surfaces.

11. The precision decorative resin molded product according to any one of claims 1 to 8, characterized in that the interval of the tool movement pitch when cutting each region of the mold is an interval that becomes a white gloss after molding.

12. The precision decorative resin molded product according to any one of claims 1 to 9, characterized in that the interval of the tool movement pitch when cutting each region of the mold is an interval that becomes an iridescent gloss after molding.

13. The precision decorative resin molded article according to claim 8, wherein the regular polygon is a hexagon.

14. The precision decorative resin molded article according to claim 9, wherein the natural product is a stone.

15. In a mold for forming a precision decorative resin molded article formed by injection molding in a mold, its surface has at least two or more regions, the regions are a non-cutting resin surface of the mold processed by non-cutting processing technology, a first cutting resin surface of the mold surface formed by the first cutting processing technology, a mold for forming a precision decorative resin molded article having at least two or more regions of either a second cutting resin surface of the mold surface formed by a second cutting processing technology which is a condition different from the first cutting resin surface, The mold for forming a precision decorative resin molded article, wherein in the first cutting processing technology or the second cutting processing technology, the cutting direction of the cutting tool of the first cutting processing technology is different from the cutting direction of the cutting tool of the second cutting processing technology.

16. In a precision decorative resin molding method formed by injection molding in a mold, its surface has at least two or more regions, the regions are a non-cutting resin surface by a mold surface processed by non-cutting processing technology, a first cutting resin surface formed by a mold surface formed by the first cutting processing technology, a precision decorative resin molding method having at least two or more regions of either a second cutting resin surface formed by a mold surface formed by a second cutting processing technology which is a condition different from the first cutting resin surface, The precision decorative resin molding method, wherein in the first cutting processing technology or the second cutting processing technology, the cutting direction of the cutting tool of the first cutting processing technology is different from the cutting direction of the cutting tool of the second cutting processing technology.

17. In a method for manufacturing a mold for forming a precision-decorated resin molded product that is formed by injection molding within the mold, its surface has at least two or more regions, the regions being a non-cutting resin surface of the mold processed by non-cutting machining technology, a first cutting resin surface of the mold surface formed by the first cutting machining technology, a method for manufacturing a mold for forming a precision-decorated resin molded product having at least two or more regions of either a second cutting resin surface of the mold surface formed by a second cutting machining technology that is a condition different from the first cutting resin surface, wherein the first cutting machining technology or the second cutting machining technology is characterized in that the cutting direction of the cutting tool of the first cutting machining technology is different from the cutting direction of the cutting tool of the second cutting machining technology, a method for manufacturing a mold for forming a precision-decorated resin molded product.

Images