Device and method for injection moulding

Abstract

This invention specifically relates to an apparatus for injection molding, and more particularly 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 a closed state of the mold; and an insert disposed in the injection molding space.

Description

Technical Field

[0001] This invention relates to a method and apparatus for injection molding. Prior Technology

[0002] Injection molding is a known technology for the production of micro-replicas. However, with the ever-increasing demand for precision in the produced injection-molded parts, this technology has reached its inherent limits in the polymer processing industry. Specifically, existing methods do not adequately address the growing demand for shape and positional tolerances in injection-molded parts. For example, if the front and rear sides of an injection mold need to be aligned, currently only a tolerance of approximately 10 micrometers can be achieved in producing injection-molded parts. Summary of the Invention

[0003] For injection-molded parts used in certain branches of the industry (such as information technology, laser technology, or communication network technology), these orders of magnitude are unacceptably high because accuracy requirements (especially for photoconductors) are in the micrometer or submicrometer range. With conventional machine-built production methods, further improvements to more precise production cannot be achieved due to factory production tolerances.

[0004] Injection molding technology can be extended from methods derived from the semiconductor industry to enable the production of injection-molded objects with increased accuracy.

[0005] The manufacturing and underlying methods of the machine tool and semiconductor industries differ from each other, so the accuracy achievable by manufacturing methods is not inherently scalable. In other words, achieving accuracy and surface quality that is conventionally unproducible is particularly challenging in the semiconductor industry. However, due to the potential for scaling dimensions (length: linear, area: quadratic, volume: cubic), semiconductor methods cannot be transferred to machine tools.

[0006] This creates opportunities for the further commercialization of novel injection-molded objects. Specifically, the alignment of the mold or any insert therein has not been adequately performed until now. Molds or inserts with corresponding molding surfaces are typically used to transfer the desired structure to the injection-molded compound that subsequently cures in the mold.

[0007] Alignment of molds or inserts occurs in an open state, where two or more mold halves or sections have not yet provided an injection space for the subsequently introduced injection molding compound. After transfer to the closed state of the respective molds used for injection molding, it is no longer possible to align the mold halves or inserts / insertions positioned in the injection space with each other. Therefore, alignment errors (especially those requiring correction for the high demands of micro-injection molded objects) can occur only in the open state of the mold. During or after mold closure, the alignment error of one of the molds or inserts / insertions can reappear. Specifically, mass production of injection-molded objects using the same molds or the same inserts / insertions for injection molding cannot therefore be performed with sufficient precision.

[0008] Therefore, the problem of the present invention is to provide an apparatus and a method that at least partially, and specifically completely, overcome the disadvantages of the prior art. The problem of the present invention also provides an improved apparatus and an improved method for injection molding.

[0009] Specifically, the problem of this invention is to provide an apparatus and a method for increasing the production precision of components or injection-molded articles produced therefrom.

[0010] The current problem is solved by the features of a coordinated technical solution. Advantageous developments of the invention are specified in the sub-technical solutions. All combinations of at least two features specified in the description, technical solutions, and / or drawings also fall within the scope of the invention. Values ​​within the stated range, those falling within the stated limits, should also be considered as limiting values ​​and can be claimed in any combination.

[0011] Therefore, the present invention relates to an apparatus for injection molding, and more particularly 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 when the mold is closed. - At least one insert disposed in the injection molding space, wherein the at least one insert comprises at least a portion of a polymer.

[0012] The mold includes at least one insert, which at least partially comprises a polymer. The device may also include two or more inserts, each of which at least partially comprises a polymer.

[0013] In the closed state of the mold, the at least one insert can be preferably (specifically) aligned with a further insert.

[0014] Furthermore, the present invention relates to a method for injection molding, specifically micro-injection molding, wherein an injection molding space is defined in the closed state of the mold by a mold having a first mold half and a second mold half, wherein at least one insert disposed in the injection molding space comprises at least a polymer.

[0015] Two or more inserts may also be disposed in the injection molding space, and such inserts at least partially comprise a polymer.

[0016] The at least one insert is preferably aligned with a further insert in the closed state of the mold.

[0017] In one particularly preferred embodiment of the invention, the at least one insert comprises an elastic surface made of a structured, molded polymer, specifically produced by imprinting. In other words, the at least one insert or its surface may represent a structured soft mold, which serves as a master mold for the primary shaping of the injection-molded article.

[0018] The elastic surface made of a structured, molded polymer will be referred to as an elastic structure in the following text. In one particularly preferred embodiment of the invention, the insert includes a substrate (back plane), specifically a plate, or more preferably a wafer, on which the structured polymer is deposited and imprinted to produce the elastic structure. In this case, the at least one insert comprises a group of at least two components (i.e., a substrate and a flexible mold imprinted thereon). The substrate specifically serves as a carrier substrate for the flexible mold.

[0019] Specifically, the at least one insert is constructed such that it at least partially comprises a polymeric material.

[0020] In one particular embodiment, the at least one insert includes at least a portion of an elastomer.

[0021] In a particularly preferred embodiment, the insert (specifically, the resilient structure) comprises at least one of the following materials: Polysiloxane · Ethylene functional polymers Vinyl-terminated polydimethylsiloxane, specifically CAS: 68083-12-2 • Vinyl-terminated biphenylsiloxane-dimethylsiloxane copolymer, specifically CAS: 68951-96-2 Vinyl-terminated polyphenylmethylsiloxane, specifically CAS: 225927-21-9 Vinylphenylmethyl-terminated vinylphenyl silicate copolymer, specifically CAS: 8027-82-1 • Vinyl-terminated trifluoropropylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 68951-98-4 • Trimethylsiloxy-terminated vinylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 67762-94-1 • Silicon alcohol-terminated vinylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 67923-19-7 • Vinyl-terminated vinylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 68083-18-1 Vinyl rubber Vinyl Q resin dispersion, specifically CAS: 68584-83-8 Vinylmethylsiloxane homopolymer, specifically CAS: 68037-87-6 • Vinyl T-structure polymer, specifically CAS: 126681-51-9 • Monovinyl-functionalized polydimethylsiloxane, symmetrical or asymmetrical, specifically CAS: 689252-00-1 Vinylmethylsiloxane terpolymer, specifically CAS: 597543-32-3 Vinyl methoxysiloxane homopolymer, specifically CAS: 131298-48-1 Vinylethoxysiloxane homopolymer, specifically CAS: 29434-25-1 Vinylethoxysiloxane-propylethoxysiloxane copolymer ·Hydride functional polymers • Hydrogenated polydimethylsiloxane, specifically CAS: 70900-21-9 Hydrogenated polyphenylmethylsiloxane • Trimethylsiloxy-terminated methylhydrosiloxane-dimethylsiloxane copolymer, specifically CAS: 68037-59-2 • Hydrogenated methylhydrosiloxane-dimethylsiloxane copolymer, specifically CAS: 69013-23-6 • Trimethylsiloxy-terminated polymethylhydrosiloxane, specifically CAS: 63148-57-2 • Triethylsiloxy-terminated polyethylhydrosiloxane, specifically CAS: 24979-95-1 • Hydrogenated polyphenylene dimethylhydrosiloxane • Hydrogenated methylhydrosiloxane-phenylmethylsiloxane copolymer, specifically CAS: 115487-49-5 • Methylhydrosiloxane-octylmethylsiloxane copolymers and terpolymers, specifically CAS: 68554-69-8 • Hydrogenated Q resin, specifically CAS: 68988-57-8 ·Silicone functional polymers • Silicon alcohol-terminated polydimethylsiloxane, specifically CAS: 70131-67-8 • Silicon alcohol-terminated biphenylsiloxane–dimethylsiloxane copolymer, specifically CAS: 68951-93-9 and / or CAS: 68083-14-7 • Silicon alcohol-terminated polyphenylsiloxane, specifically CAS: 63148-59-4 • Silicon alcohol-terminated polytrifluoropropylmethylsiloxane, specifically CAS: 68607-77-2 • Silicon alcohol-trimethylsilyl modified Q resin, specifically CAS: 56275-01-5 Amine-functionalized polysiloxane • Aminopropyl-terminated polydimethylsiloxane, specifically CAS: 106214-84-0 • N-Ethylaminoisobutyl-terminated polydimethylsiloxane, specifically CAS: 254891-17-3 • Aminopropylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 99363-37-8 • Aminoethylaminopropylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 71750-79-3 • Aminoethylaminoisobutylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 106842-44-8 • Aminoethylaminopropylmethoxysiloxane-dimethylsiloxane copolymer, specifically CAS: 67923-07-3 • Hindered amine functionalized siloxanes Tetramethylpiperidinyloxypropylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 182635-99-0 • Epoxy-functionalized polysiloxane • Propylene oxide-terminated polymethylsiloxane, specifically CAS: 102782-97-8 • Propyleneoxypropyl methylsiloxane-dimethylsiloxane copolymer, specifically CAS: 68440-71-7 • Glycol-terminated polyphenylmethylsiloxane, specifically CAS: 102782-98-9 • Glycidoxypropyl dimethoxysilyl-terminated polydimethylsiloxane, specifically CAS: 188958-73-8 • Tris(glycidoxypropyl dimethylsiloxy)phenylsilane, specifically CAS: 90393-83-2 • Mono-(2,3-epoxy)-propyl ether-terminated dimethoxysiloxane, specifically CAS: 127947-26-6 • Epoxycyclohexylethylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 67762-95-2 • (2 to 3% cyclohexyl ethyl methyl silicate)(10 to 15% methoxy poly(alkyl methyl silicate))-dimethyl silicate terpolymer, specifically CAS: 69669-36-9 Cycloaliphatic epoxy silanes and polysiloxanes • Epoxycyclohexylethylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 67762-95-2 • (2 to 3% cyclohexyl ethyl methyl silicate)(10 to 15% methoxy poly(alkyl methyl silicate))-dimethyl silicate terpolymer, specifically CAS: 69669-36-9 • Epoxycyclohexylethyl-terminated polydimethylsiloxane, specifically CAS: 102782-98-9 Methanol-functionalized polysiloxane • Methanol-hydroxyl-terminated polydimethylsiloxane, specifically CAS: 156327-07-0, CAS: 10478066-7, CAS: 68937-54-2, CAS: 161755-53-9, CAS: 120359-07-1 • Bis(hydroxyethyl)amine-terminated polydimethylsiloxane • Methanol-functionalized methylsiloxane-dimethylsiloxane copolymer, specifically CAS: 68937-54-2, CAS: 68957-00-6, CAS: 200443-93-2 • Mono-methanol-terminated polydimethylsiloxane, specifically CAS: 207308-30-3 • Mono-methanol-terminated polydimethylsiloxane, specifically CAS: 218131-11-4 · Methacrylates and acrylate-functionalized siloxanes • Methacryloxypropyl-terminated polydimethylsiloxane, specifically CAS: 58130-03-3 • (3-Acryloyloxy-2-hydroxypropoxypropyl)-terminated polydimethylsiloxane, specifically CAS: 128754-61-0 • Acrylonitrile-terminated ethylene oxide-dimethylsiloxane-ethylene oxide ABA block copolymer, specifically CAS: 117440-21-9 • Methacryloxypropyl-terminated branched polydimethylsiloxane, specifically CAS: 80722-63-0 • Methacryloxypropylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 104780-61-2 • Acryloyloxypropylmethylsiloxane-dimethylsiloxane copolymer, specifically CAS: 158061-40-6 • (3-Acryloyloxy-2-hydroxypropoxypropyl)methylsiloxane-dimethylsiloxane copolymer • Methacryloxypropyl T-structure siloxane, CAS: 67923-18-6 · Acryloyloxypropyl T-structure siloxane • Polyhedral silicone oligomers (POSS) Tetraethyl orthosilicate (TEOS) Poly(organo)siloxane • Polyhedral silicone oligomers (POSS) Polydimethylsiloxane (PDMS) Tetraethyl orthosilicate (TEOS) • Poly(organo)siloxanes (siloxanes) • Perfluoropolyether (PFPE).

[0022] Specifically, the mold is constructed such that, in one of the open states of the mold, at least one insert is inserted into and, specifically, secured in the first mold half or the second mold half. In the closed state, the mold internally includes the injection molding space, which is formed by the first and second mold halves.

[0023] The at least one insert is disposed in the injection molding space and can be preferably aligned. Thus, the alignment of one of the at least one insert can advantageously occur in the closed state of the mold and can correct for an alignment error.

[0024] Specifically, the layout is configured such that the at least one insert can move in one or more directions relative to the mold or the injection molding space. The alignment error is preferably determined by measuring an injection-molded article produced by injection molding.

[0025] This apparatus and method are preferably designed for the mass production of injection-molded objects where there are particularly high requirements for the accuracy of the shape of the injection-molded parts. Specifically, injection-molded parts including functional areas can be produced by this apparatus and method. These functional areas are specifically molded onto the injection-molded part by means of an insert that can be aligned with at least one insert, specifically during the curing of an injection molding compound introduced into the mold.

[0026] In one preferred embodiment of the invention, the device is configured such that it includes at least one further insert disposed in the injection molding space, wherein the insert and / or the at least one further insert are alignable in the closed state of the mold. Thus, the injection-molded article can be formed or produced together with a plurality of inserts.

[0027] Furthermore, these inserts are advantageously aligned with each other in the closed state of the mold. In addition to the flexible design of the injection-molded article, it is advantageous to achieve precise alignment of the production process by aligning one of the two inserts. In this embodiment, one insert is specifically disposed in the first mold half and the at least one further insert is disposed in the second mold half.

[0028] In another preferred embodiment of the invention, the layout is performed such that the insert and / or the at least one further insert, in each case, includes a molded surface having an elastic structure. The shape of the injection-molded article can be advantageously predefined by these molded surfaces.

[0029] These flexible structures, especially small, specifically microstructures and / or nanostructures, can be advantageously molded onto the injection-molded part in an injection molding process. The flexibility of these structures allows for even finer and more precise molding of these structures onto the injection-molded object.

[0030] Specifically, interlocking or undercut shapes can also be molded. Rigid structures can destroy these microstructures and / or nanostructures or destroy themselves during removal from the mold. Tilted microstructures and / or nanostructures are mentioned as an example.

[0031] With this structured molding surface, multiple injection-molded parts with very high requirements can be better mass-produced by injection molding. Therefore, a production process is provided that enables cost-effective, rapid, and high-quality production of injection-molded parts.

[0032] These elastic structures are preferably made of a polymer used in the semiconductor industry for flexible printing. Such polymers are mentioned in, for example, publications WO2015078520 A1 and WO2014202127 A1.

[0033] In another preferred embodiment of the invention, the molding surfaces of the at least one insert and the at least one further insert are aligned with each other in the closed state of the mold. With the molding surfaces of the inserts aligned with each other, the shape of the injection-molded article can be predefined with extreme precision. By aligning the molding surfaces of the inserts in the closed state of the mold, the position or location of the molding surfaces relative to each other can be advantageously predefined with particular precision.

[0034] In another preferred embodiment of the invention, the layout is made such that the structures of the molded surface of the at least one insert and the structures of the molded surface of the at least one further insert can be aligned with each other in the closed state of the mold.

[0035] With the elastic structures disposed on the molding surfaces aligned relative to each other, the positions of the molding structures on the front and rear sides of the injection-molded part can be advantageously and precisely adjusted relative to each other. Specifically, one requirement for some applications is that not only are specific shapes and structures molded particularly precisely onto the injection-molded compound or the injection-molded part, but also that the molding shapes and structures are molded onto the injection-molded part with as much precision as possible relative to their respective positions.

[0036] In another preferred embodiment of the invention, the arrangement is such that at least one heating element is integrated into at least one of the mold halves and / or the at least one insert and / or the at least one further insert and / or each structure, such that the injection molding space (specifically, one of the injection-molded compounds delivered to the injection molding space) can be heated in a calibrated manner by the at least one heating element.

[0037] The heating element can be of any type. A resistance heating element or an induction heating element is conceivable, for example. Induction heating advantageously heats the mold or the insert or the interface of such inserts (specifically, the molding surfaces having an elastic structure that directly contacts the injection molding compound during the injection molding process). Uncontrolled solidification of the injection molding compound (specifically, at the fine structures of the molding surfaces of such inserts) is thus prevented, and the fluid molding compound can advantageously remain uniformly heated during the injection molding process. Furthermore, molding quality is improved, or a molding defect on the injection-molded object to be produced is prevented. Specifically, molding of such microstructures and / or nanostructures is improved and simplified by heating the molding surfaces or heating the structure.

[0038] In one particularly preferred embodiment of the invention, the heating element is incorporated into the at least one insert. If the at least one insert is a semiconductor, the heating element is directly designed as an active element, i.e., a metal strip conductor or a semiconductor element, which are suitable for efficiently converting current into Joule heat and are directly manufactured in the at least one insert. This achieves highly efficient heating. The heating is preferably designed as in disclosure WO 2019210976.

[0039] In another preferred embodiment of the invention, the at least one insert and / or the at least one further insert (specifically on their respective molded surfaces and / or on their respective rear sides) are configured such that they include a plurality of alignment marks. These alignment marks are markers that can assign a specific location on the insert.

[0040] Specifically, these are regularly arranged alignment marks, specifically an alignment mark field, wherein each alignment mark can be assigned a specific position within the alignment mark field. In the case of these alignment marks on the molded surface, specifically, they can be a structure disposed on the molded surface of the at least one insert.

[0041] The at least one insert preferably has alignment marks on the mold surface and the rear side. The position of the alignment marks on the mold surface is particularly preferably known for the position of the alignment marks on the rear side of the at least one insert.

[0042] These alignment marks can be better detected, processed, and positioned in a relative position by means of an optical alignment member. These alignment marks can be, for example, disposed inside the mold, specifically on the rear side of the at least one insert. The alignment marks enable particularly precise and direct alignment of the at least one insert.

[0043] In another preferred embodiment of the invention, the mold is configured such that the first mold half and / or the second mold half includes a detection window, allowing the at least one insert and / or the at least one further insert to be aligned and / or aligned with each other in the closed state of the mold by means of the plurality of alignment marks. The detection window (or a plurality of detection windows) is disposed in the mold such that the alignment marks of the at least one insert and / or the at least one further insert are visible from the outside of the mold, specifically visible or detectable to an optical alignment member.

[0044] The insert / the inserts can therefore be aligned / aligned with each other. The detection window is preferably disposed in the mold such that, in the closed state of the mold, the alignment marks on the rear side of at least one insert are visible. Thus, it is advantageous to perform relative alignment of one of the respective inserts by monitoring.

[0045] In another preferred embodiment of the invention, the mold is constructed such that each of the first mold half and / or the second mold half includes at least one positioning mechanism, enabling the at least one insert and / or the at least one further insert to be aligned in the closed state of the mold by means of the plurality of alignment marks. The positioning structure can, specifically, advantageously perform the alignment of the at least one insert and / or the at least one further insert in an automated or computer-controlled manner when the mold is closed.

[0046] The alignment is advantageously performed using these alignment marks. Specifically, the positioning mechanism is designed such that the at least one insert or inserts can be aligned with particular precision. The positioning mechanism is preferably an aligner. The insert to be aligned is fixed in the mold but can be aligned by the positioning mechanism. Therefore, the at least one insert can be advantageously aligned in a closed mold using these alignment marks.

[0047] In another preferred embodiment of the invention, a layout is made such that the structure of the molded surface of the at least one insert and the structure of the molded surface of the at least one further insert can be aligned with each other in the closed state of the mold by means of the plurality of alignment marks on the rear side of the at least one insert and / or the rear side of the at least one further insert. In this embodiment, the position of the alignment marks on the rear side of the at least one insert relative to the structure of the molded surface of the at least one further insert is known. The insert and / or the structures (specifically, those important for molding on the injection-molded article) can therefore be aligned or aligned with each other in the closed mold solely by means of the alignment marks on their respective rear sides. Thus, alignment of one of the structures on the molded surfaces of the inserts is advantageously possible solely by means of the alignment marks on the rear sides. Alignment by means of one of the alignment marks on the rear side of the insert can also be performed (for example) during the injection molding process.

[0048] In another preferred embodiment of the method according to the invention, a layout is performed such that the at least one insert and at least one further insert (specifically, a molded surface of the at least one insert and / or a molded surface of the at least one further insert) disposed in the injection molding space are aligned with each other in the closed state of the mold within the injection molding space. The molded surfaces of these inserts (specifically, the structures disposed on these molded surfaces) can thus be aligned or aligned with each other by means of this method. Therefore, the accuracy of the shape of the produced injection-molded article is advantageously increased during injection molding.

[0049] In another preferred embodiment of the method according to the invention, the layout is performed such that the at least one insert and / or the at least one further insert are aligned by means of a plurality of alignment marks disposed on the insert and / or the at least one further insert. The at least one insert and / or the at least one further insert can therefore be advantageously aligned by means of these alignment marks.

[0050] In another preferred embodiment of the method according to the invention, a layout is performed such that the alignment of at least one insert and / or at least one further insert is performed based on a measurement of an injection-molded article produced according to the injection molding method. After the production of an injection-molded article, the latter can be measured and analyzed. The actual values ​​of the shape and geometry of the injection-molded article are compared with set values. A shape defect can be identified from this comparison, and a correction can be derived. By realigning the insert or the inserts, this error can be repeatedly improved by repeatedly performing the alignment, specifically until the shape defect is within a predefined tolerance range. Preferably, the regions of the injection-molded article in which the structures molded onto the molding surfaces are measured are particularly important for the functionality of the produced injection-molded article. Therefore, an improvement can be achieved by means of the alignment of a produced injection-molded article.

[0051] In another preferred embodiment of the method according to the invention, a layout is performed such that alignment is achieved by reprocessing the at least one insert and / or the at least one further insert. A correction is performed by aligning the insert or the inserts based on a confirmed shape defect. Alignment can also be achieved by reprocessing (specifically, removing or applying corresponding material). For example, when the inserts are facing each other, a shape defect in the injection-molded article may arise due to the inaccurate parallelism of the inserts relative to each other. Specifically, this can occur by removing material from the insert (specifically, on the rear side). For example, laser radiation can be used for this purpose. Thus, defects in the shape of the injection-molded article that cannot be compensated for by alignment using a positioning mechanism can be advantageously compensated.

[0052] In another preferred embodiment of the method according to the present invention, deployment is performed such that the method comprises at least the following steps, specifically the following sequence: i) The mold is equipped with the insert and / or the at least one further insert. ii) Close the mold, iii) Specifically, an injection-molded article is produced by introducing and curing an injection molding compound. iv) Remove and measure the injection-molded part. v) Determine an alignment error by comparing it with a set value. vi) Align the insert and / or the at least second insert.

[0053] Therefore, these methods for injection molding can advantageously adapt the process repeatedly by aligning the inserts.

[0054] One aspect of this invention is based on a modification of the injection molding process or apparatus, enabling surfaces with micron or nanometer structures to be produced using at least partially flexible inserts (specifically, insert surfaces structured by soft molding technology). To increase injection molding accuracy, fundamental methods from the semiconductor industry are used to align or interconnect molded parts or surfaces. The accuracy of the production process can be increased or adjusted by measuring the produced injection-molded parts or final products and providing feedback. In this regard, feedback means measuring batches of repeatedly produced injection-molded parts and compensating for any defects found in the injection-molded parts by aligning the inserts and / or reprocessing them, allowing for iterative improvement of the quality of the injection-molded parts produced in each case.

[0055] By utilizing the apparatus and method according to the invention, one of the surfaces of an embossed workpiece is functionalized, thereby reducing production costs and simultaneously increasing the precision of the workpiece through optimization of a given production process. In other words, a conventional production process can be used for shaping. Specifically, the surface functionalization is achieved using at least one novel, high-precision insert in the mold. To date, conventional injection molding apparatus or methods have been unable to produce injection-molded articles with functional surfaces or microstructured and / or nanostructured surfaces.

[0056] This invention relates to a method and apparatus for injection molding (specifically, micro-injection molding). Therefore, it relates to the production of injection-molded articles having very small structures, which are molded onto an injection-molded compound or a corresponding injection-molded article by means of a molding surface.

[0057] A known injection molding apparatus is designed such that the accuracy and / or dimensional and positional tolerances and / or surface quality and / or surface functionalization of the injection molded parts produced are improved by, in particular, at least partially flexible, and better microstructured inserts.

[0058] In injection molding, an injection-molded part is typically produced in a mold or injection space (also called an injection chamber) of a master shape, wherein the mold is filled with an injection molding compound. This injection molding compound exhibits specific state variables related to specific volume, temperature, and filling pressure. The mold is filled under high pressure with a compressible and compressed injection molding compound, which is heated to above its melting temperature and subjected to a holding pressure. The temperature of the injection molding compound is specifically 10°C, preferably 25°C, more preferably 50°C, and most preferably 75°C above its melting temperature. The melt solidifies in the mold under this holding pressure.

[0059] After the phase transition to solid state (with physically determined and unavoidable shrinkage), and specifically after atmospheric pressure is reached in the mold, the mold opens at least on a mold separation plane and automatically removes or ejects the molded object.

[0060] The mold's condition, material, temperature, pressure, and design and / or functionalization are responsible for the achievable dimensional accuracy of the injection-molded part.

[0061] The first disclosed injection molding apparatus includes at least one modified mold having at least one insert for adaptation and / or functionalization of the mold and the injection molded articles produced therefrom.

[0062] The insert preferably has a specific microstructure or nanostructured surface that is replicated during the production of the injection-molded article.

[0063] The at least one insert preferably has a coating, more preferably a structured coating, and more preferably a microstructured or nanostructured coating, which is replicated during the production of the injection-molded article.

[0064] Preferably, the at least one insert has an elastic structure, specifically a microstructure and / or nanostructure. Specifically, an insert with at least a partially rigid structure on its surface can thus produce injection molded articles with high precision, high surface texture requirements, and / or narrow shape or position tolerances.

[0065] Preferably, a functional separation is performed, specifically between the rough shaping and functionalization of at least one object surface, whereby the shape and design of the mold and / or the at least one insert at least establish the rough shaping and the specific elastic structuring of the insert surface (which is replicated in the injection molded article) determines the surface of the injection molded article or the functionalization of the surface of the injection molded article.

[0066] It is conceivable to incorporate an additional, localized heating element into at least one, specifically microstructured or nanostructured insert, in order to increase the accuracy of the shaped profile and obtain a higher aspect ratio, i.e., to enable the production of taller and narrower structures.

[0067] It is also conceivable to couple the heating element into the surface structure of the at least one insert to agitate the injection-molded compound in a calibrated manner and directly in the area in contact with the injection-molded compound. The aspect ratio of the structured molding surface can thus be further improved.

[0068] Specifically, an independent invention can be seen in the mold of an injection molding apparatus according to one of the present invention. The mold parts, which are not primarily related to the function of the injection molded article, can be designed using conventional manufacturing methods according to ISO 2768-1 and ISO 2768-2, which are specifically classified as "fine" or "high".

[0069] The mold contains at least one insert. The at least one insert can be applied to the surface of the insert to be molded by an embossing process and is therefore functionalizable.

[0070] At least one insert with higher requirements for surface quality and functionality (such as, specifically, microstructured periodic surface structures) is preferably produced using so-called micro-replication (specifically, micro or nano-microlithography) and integrated into the mold as at least one partially elastic insert. Due to this surface coating by the lithography process, the at least partially elastic structures on the at least one insert can be advantageously and precisely replicated individually on the injection-molded article.

[0071] The surface structure of the at least one insert is (e.g.) produced on the given insert by a photolithography technique, specifically similar to the technique described in detail in Publication EP2870510B1.

[0072] The at least one insert, which may contain, for example, an inorganic carrier (preferably a semiconductor material, and / or particularly preferably SiN and / or SiC and / or diamond and / or technical glass), is preferably fixed in the mold in a manner that allows for alignment. The at least one insert is thus partially fixed, but can be moved in a calibrated manner and therefore can be fixedly mounted in another location.

[0073] Alternatively, it is conceivable to first create a specific elastic structure on a carrier using known imprinting techniques, and then transfer it to the surface of the at least one insert. For this transfer, specific plasma activation and / or adhesives can be used. However, it is preferable that the elastic structure is created directly on the surface of the at least one insert. An aligner can be used for alignment and / or pre-fixation structuring on the surface of the at least one insert. For example, a processing laser can be used to fix the carrier to the at least one insert or to integrate it into the mold.

[0074] In one particularly advantageous embodiment of the mold, the at least one insert can be aligned and secured in the mold using an aligner known from semiconductor technology. In this case, specifically in the transverse plane of the mold, the alignment accuracy of the at least one insert in the mold is better than 5 µm, more preferably better than 1 µm, particularly better than 500 nm, and extremely better than 250 nm. The same alignment accuracy can be provided in different directions of movement of the mold by means of this aligner or other aligners.

[0075] Preferably, the alignment accuracy of the at least one insert in the mold is measured on the produced injection-molded part. Therefore, in a batch production process, the first and first produced injection-molded parts can be measured, and the alignment accuracy can be determined by comparing the measured actual value with one of the predefined set values.

[0076] An alignment device is preferably integrated as an alignment module into the injection molding apparatus. Therefore, with a modular design, a device having modules (such as a measurement module for measuring injection-molded parts, a material preparation module) can be added to the injection molding apparatus in a flexible manner and according to application requirements.

[0077] Specifically, it is conceivable to modify a so-called mask aligner from the semiconductor industry to enable the use of existing optical systems that generate monochromatic UV radiation. Therefore, it is also conceivable that the injection molding apparatus includes an aligner and an imprinter for creating, specifically, a flexible microstructured or nanostructured surface on an insert.

[0078] Furthermore, it is preferable to specifically use high-energy radiation (specifically, a laser or heating) to align at least one insert in the mold in a combined aligner and pre-fix the aligner in the mold, such that the insert with an elastic surface coating is fixed in the mold in the proper position and the mold is movable.

[0079] "Fixed" refers to the connection of at least one insert to one of the molds, the connection being adapted or designed for operating conditions (pressures exceeding 2000 bar, preferably exceeding 2400 bar, and temperatures of the imprinting compound and mold exceeding 150 degrees Celsius, preferably exceeding 200 degrees Celsius). Due to this fixation, the at least one insert is secured in the mold in the appropriate positioning and location, specifically without constraint.

[0080] The unconstrained fixation of the at least one insert in the mold means that six precise degrees of freedom of movement are obtained from the at least one insert. This advantageously prevents deformation due to parasitic forces on the insert.

[0081] The accuracy of the alignment between these inserts (measured again on the injection-molded part) is referred to by those skilled in the art as the resulting alignment error. Therefore, this alignment error exists relative to the insert and a second component (specifically, a further insert).

[0082] The alignment error on the injection-molded part (specifically, relative measurement for two inserts facing each other with their respective molding surfaces) is preferably less than 10 μm, preferably less than 5 μm, particularly preferably less than 1 μm, extremely preferably less than 500 nm, and most preferably less than 200 nm.

[0083] Smaller alignment errors are necessary for specific (and particularly optical) applications. Therefore, the alignment error on the injection-molded part is less than 150 nm, preferably less than 100 nm, and especially preferably less than 50 nm.

[0084] In cases where periodic (preferably identical or periodically repeating) structures are molded in the injection-molded article, the alignment of the periods with each other is important for the functionality.

[0085] Whether these cycles are aligned with each other in a "peak-to-peak," "valley-to-valley," or "valley-to-peak" manner is irrelevant to considerations of the periodicity error on the injection-molded part. Therefore, the periodicity error is considered a deviation from an ideal, predefined alignment state. Only deviations are counted, i.e., defects on the injection-molded part. Thus, it is advantageous to indicate the alignment state of these cycles relative to each other as a quality characteristic. A precise alignment error for one cycle causes only one error at the edge of the embossed structure of the injection-molded part; in other words, a shift in the length of one cycle.

[0086] The alignment error (specifically, the periodic error) should total less than 0.25 cycles as measured on the injection-molded part, preferably less than 0.1 cycles, and particularly preferably less than 0.05 cycles.

[0087] This alignment error must also be minimized relative to the rotational system. At a distance of 50 mm, these structures should not deviate by more than 0.5 μm. This corresponds to a maximum angle of 10⁻⁵°. Therefore, the alignment error with respect to this angle is less than 10⁻⁵°, preferably less than 10⁻⁶°, and still more preferably less than... 10⁻⁷°, optimally less than 10⁻⁸°, optimally less than 10⁻⁹°.

[0088] In other words, a rotational error of a reference length of 50 mm is less than 1 µm, preferably less than 500 nm, more preferably less than 250 nm, and most preferably less than 100 nm, when measured at the periphery and / or edge of the object.

[0089] In a preferred embodiment of the injection molding apparatus, the injection molding compound may contain a photocurable, specifically a UV-curable component. By using this injection molding compound, no thermally dependent curing or phase transition from a liquid to a solid occurs; instead, a phase transition is based on UV radiation.

[0090] In this embodiment of the injection molding apparatus, the mold includes an integrated radiation source and / or radiation windows, which are transparent to the curing radiation system, and the curing radiation irradiates the injection-molded compound through the radiation windows to initiate curing. In a preferred embodiment, the mold is transparent.

[0091] Technical polymers and / or so-called commodity plastics, in other words, polymers derived from mass production, can be used as injection molding compounds. Material selection is guided by the intended use of the injection-molded article.

[0092] Polymers and / or mixtures and / or blends thereof may be used with or without fillers, wherein the fillers specifically contain the following materials: -POSS -Polyethylene (LDPE, HDPE) and / or - Polypropylene (PP, and 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.

[0093] The total shrinkage of the injection molding compound used is preferably less than 5%, particularly preferably less than 3%, still more preferably less than 1.7%, and most preferably less than 0.7%.

[0094] A second embodiment of an injection molding apparatus includes at least one modified mold having two inserts that are aligned with each other and perform functionalization of the injection molded article having a specific elasticity, better microstructured and / or nanostructured surface.

[0095] In this embodiment of the injection molding apparatus, at least two inserts having a specific elastic microstructured and / or nanostructured insert surface can be aligned with each other and fixed in the mold.

[0096] The total alignment accuracy of the inserts in the mold is the same as the alignment accuracy of a single insert in the mold.

[0097] The inserts can be positioned in the mold such that they fall on different mold halves of the mold's separation plane. Therefore, the apparatus and method for injection molding can be designed with particular flexibility regarding the position of the inserts in the mold.

[0098] To perform the alignment process of these inserts with high accuracy, the mold can be designed to be at least partially transparent. In other words, the mold can have removable support parts (for force transmission and uniform force distribution of contact pressure) and inspection and alignment windows, by means of which the alignment of the inserts or their structured surfaces can be performed in a fully closed state of the mold. To absorb force and temperature fluctuations during the injection molding process of the inserts with specific elasticity and microstructure, and the inspection and / or alignment windows, the mold can contain corresponding support structures. These inspection windows can also be specifically designed to cure the injection-molded compound using UV radiation.

[0099] In order to perform a precise alignment of the inserts / the inserts in the at least two mold halves of the mold, the inserts must be aligned with each other in the closed mold. Therefore, alignment errors of the inserts or the inserts with each other, which occur during closure, in the closed state of the mold, or while fixed in the mold, can be compensated or corrected.

[0100] Alignment can be performed, for example, by means of so-called alignment marks or markers. The latter are applied to the insert or such inserts. Preferably, at least one marker is present on each insert, which can be aligned in the closed state of the mold.

[0101] Alignment is preferably performed by optical alignment using one of at least one of the alignment marks disposed on the rear side of a further insert. Thus, alignment can advantageously be performed via the rear sides of the inserts opposite to their respective molded surfaces.

[0102] In the semiconductor industry, such markings or alignment marks may include standard crosses, propeller-shaped alignment marks, circles, polygonal patterns, linear patterns for optical interference, and QR codes.

[0103] These alignment marks are preferably arranged in a mark field, wherein each alignment mark has information content that indicates its position in the mark field and thus the position of the corresponding insert relative to an optical alignment member. Then, based on the known positions of the individual marks in the mark field, an alignment can be advantageously performed relative to each other.

[0104] It is particularly advantageous for an insert to have alignment marks or symbols on its two opposing surfaces. These alignment marks or symbols are preferably positioned on the respective rear side of the insert and on the respective sides of the molded surfaces of the insert. Thus, alignment can be advantageously performed from both sides of the insert.

[0105] Preferably, the injection molding apparatus includes an aligner and a retainer for one of the two inserts, wherein the aligner performs an association between surface structuring on the molding surface and alignment marks on the rear side of the insert, the surface structuring then specifically serving as alignment marks, wherein the association is specifically based on image evaluation. Using the associated data, rear-to-rear alignment of at least one of the two inserts can be performed. Optical alignment members for detecting the respective alignment marks on the rear side can be disposed inside the mold. Therefore, the mutual alignment of the inserts can advantageously be performed in the closed state of the mold.

[0106] Alignment can also be conceived by means of alignment members disposed on the outside of the mold, such alignment members being able to detect, for example, the alignment marks or symbols of the inserts through channels or detection windows.

[0107] The surface structuring of the insert can specifically be performed in an aligned manner on the insert surface or the molded surface, allowing for the measurement of the position and location of the specific soft surface structure. In this case, such surface structures can advantageously serve as alignment marks or markers. Specifically, it is conceivable that the insert has further markings or alignment marks on its rear side, which can be measured relative to such surface structures. Therefore, when the mark is measured, the position of the relative surface structure is also known, and vice versa.

[0108] The insert may include different areas or layers of the surface structures. These surface structures may contain surface structures to be copied and / or surface structures not to be copied, specifically alignment marks. These surface structures may be formed in a so-called "first print" or in sequential production.

[0109] In one advantageous embodiment of the device, markings (specifically, alignment marks) may be provided and / or applied and / or introduced on, specifically, the surface of the insert having the soft structure to be copied and the surface of the insert opposite to the soft structure. In other words, the insert may contain alignment marks and / or alignment mark fields on both surfaces, which, specifically, enable the insert to be properly aligned in an aligner by means of lithography or an electron beam.

[0110] The alignment marks of the surface structure are preferably measured relative to the same surface of the insert so that the position of the surface structure on the insert can be verified.

[0111] Particularly preferably, the alignment marks of the surface-structured insert are provided for measurement and reference of the alignment marks on the non-surface-structured (imprinted) side of the insert. In other words, an association is formed between the surface structure (specifically, its position and / or positioning) and the rear side of the insert. Thus, the surface structures of the inserts can be aligned with each other such that they are not directly optically accessible to an aligner. By means of the association between the front and rear sides of the inserts, the inserts can be aligned with each other based on the rear side of the non-surface-structured (imprinted) insert, as if the surface structures were directly aligned with each other.

[0112] Ideally, the alignment of these inserts is performed within a closed mold.

[0113] Since all surface-structured inserts are measurable and can be correlated with each other, the measured alignment error of the injection-molded part can be correlated by means of error correction vectors derived from the alignment error of the injection-molded part, so that the inserts are better aligned with each other.

[0114] Alignment success is checked by measuring the injection-molded parts produced or by determining alignment errors based on the injection-molded parts produced.

[0115] Specifically, the arrangement is made so that the inserts can be positioned or aligned in a closed mold by means of a feed motion of less than 1000 µm, preferably less than 500 µm, and especially more preferably less than 250 µm, specifically by means of a flexible bearing (specifically, without clearance).

[0116] In a further preferred embodiment, an air bearing integrated into the mold facilitates the movement of the inserts. This achieves easy and highly precise alignment.

[0117] In other words, the feeding motion means the maximum possible travel of the insert in the mold during alignment.

[0118] Based on the maximum travel or maximum possible feed motion, the alignment marks should cover at least an area greater than the sum of the vectors of the travel vectors of the positioning or alignment device. For example, if it is possible to travel 1 mm in the x-direction and also 1 mm in the y-direction, then the alignment marks should appear in an area greater than 1 mm^2 in the field of view of the aligner.

[0119] The placement is carried out so that the inserts can be positioned by a precision positioner, specifically by a piezoelectric actuator and / or a differential screw actuator.

[0120] For example, piezoelectric actuators, linear piezoelectric actuators, screwdrivers, etc. can be used.

[0121] The inserts are also arranged so that they are aligned and fixed in the mold, such that the production of a series of injection-molded articles, or at least one statistically relevant sample of injection-molded articles, results in the positional and positioning displacement of the inserts being less than 1%, preferably less than 50 ppm, and particularly preferably less than 100 ppb. This displacement is related to the ideal value of the produced articles. In other words, the dispersion of the production error relating to the position and / or positioning of the inserts is kept within a narrow tolerance range of less than 1%, preferably less than 50 ppm, and particularly preferably less than 100 ppb.

[0122] Once the position and positioning of these inserts in the mold have been repeatedly corrected, the effect is accompanied by the minimization of production errors on the injection molded part, and these inserts can be fixed in the mold for mass production in a specific context.

[0123] In this case, fixation is understood to mean that the insert cannot be separated from the mold without damage (specifically due to its high adhesion to one of the molds).

[0124] It is conceivable that a fixed insert needs to be replaced. In this case, the insert may be destroyed, but the functionality of the mold should be preserved, except for necessary cleaning, and it should be able to accommodate a further insert without reworking the mold.

[0125] In a preferred embodiment of the mold in the injection molding apparatus, the mold is advantageously arranged such that, specifically by reprocessing the elastic surface structure of at least one of the inserts and / or by reprocessing at least one of the inserts, the shape and positioning tolerance of the injection-molded article is increased by the disclosed method. Specifically, the planar parallelism of the injection-molded article can be improved.

[0126] Furthermore, deployment is carried out so that the insert or the mold or configuration of such inserts can be adjusted in an iterative, specific, approximate verification process.

[0127] A mold is formed, and the mold is used to produce a specific, statistically relevant number of injection-molded objects, specifically, batch injection-molded objects.

[0128] These injection-molded parts are measured and specifically statistically evaluated. Therefore, an average alignment error can be advantageously identified.

[0129] The mold can then be corrected based on this, specifically the insert. This correction may consist, for example, of the removal or addition of material and / or a change in orientation and / or an adjustment of the insert's positioning.

[0130] Produce and evaluate calibrated injection-molded parts in a statistically relevant quantity for a specific purpose. Repeatedly perform further approximation of an ideal injection-molded part, or begin production of that injection-molded part.

[0131] To further correct errors, a statistical evaluation of a random sample of the injection-molded part can be performed to enable further necessary adjustments. Specifically, deployment can be carried out to detect aging effects and wear on the mold in advance.

[0132] In other words, before the mass production of the injection molded part, the individual molds of the injection molding device are adapted and adjusted. This improves the quality of the injection molded part and achieves a narrower tolerance, specifically in the area produced by microtechnology.

[0133] Specifically, a first preferred illustrative method for injection molding is performed in the following sequence of steps. - Provide at least one flexible microstructured or nanostructured insert for the mold. - Close the mold. - Specifically, in an integrated aligner (alignment module), the insert is aligned with the mold and / or the inserts are aligned with each other (specifically, rear side to rear side), and fixed in the mold. - Install the mold in the injection molding device. - Specifically, it refers to the production of at least one injection-molded object through an injection molding process. - Remove the injection-molded part from the mold, and specifically measure the injection-molded part in a 3D coordinate measuring machine. Transmit the data to data memory and data analysis devices. - In an optional procedure step, check and / or test the functionality of the injection-molded part. - An error vector domain is generated by the computer, which is derived from the measured values ​​and set values. The correction factor and correction measures are then determined. - Apply calibration and correction. - These calibration corrections include changes in the position and orientation of the at least one insert within the mold. -Optionally, one of the adjustments to the mold and the insert may be performed again.

[0134] A further preferred illustrative method for injection molding includes, specifically, the following procedural steps, specifically, the following sequence.

[0135] The mold is prepared in the fabrication process. For this purpose, it is necessary to functionalize the inserts with surface structures. The relationship between each insert is measured from these surface structures to the back side of the insert and, specifically, processed in a computer that serves as a data memory and data analysis device. - Provide the mold with specific flexible microstructured or nanostructured inserts. - Close the mold. Specifically, in the alignment unit (alignment module) integrated into the injection molding apparatus, the inserts are aligned with each other (specifically, rear side to rear side) and fixed in the mold. - Install the mold in the injection molding device. - Specifically, it refers to the production of at least one injection-molded object through an injection molding process. - Remove the injection-molded part from the mold, and specifically measure the part in a 3D coordinate measuring machine. Transmit the data to the data memory and data analysis device. - In an optional procedure step, check and / or test the functionality of the injection-molded part. - An error vector domain is generated by the computer, which is derived from the measured values ​​and set values. The correction factor and correction measures are then determined. - Apply calibration and correction.

[0136] Such corrections may include at least one of the following modifications: localized material accumulation, localized material removal, or surface structuring. Specifically, the thickness variation or waviness of the injection-molded part may change with the removal or accumulation of a specified material on the rear side of the insert.

[0137] The indentation pressure present in injection molding can be used to utilize the deformation of the insert in a calibrated manner and at least partially affect the shape of the injection-molded article.

[0138] If material is removed at least partially from the rear side of the insert, the volume of the injection-molded article increases. Therefore, local depressions in the injection-molded article can be corrected.

[0139] If material accumulates at least partially on the rear side of the insert, the volume of the injection-molded article decreases.

[0140] Those skilled in this technique may use calibration methods to accumulate layers (such as vapor deposition, PVD, CVD, or molecular beam epitaxy), or use discrete underlying films. Electron beam ablation, laser ablation, singeing, polishing, grinding, sanding, plasma treatment, or treatment with an ion gun can be envisioned for layer removal. In the sense of alignment, those skilled in this technique may use all known processing methods. - The process of installing the modified insert into the mold and starting the production of the injection molded part is repeated until a termination criterion is reached.

[0141] One possible termination criterion is achieving the qualitative and functional criteria of the injection molded part. Another termination criterion could be that one of the injection molded parts becomes irreparably deteriorated, necessitating inspection and replacement of the mold and / or the insert. Simple Explanation of the Diagram

[0142] Further advantages, features, and details of the invention will be described below from preferred embodiments and illustrated by means of drawings. In the drawings, the following is a schematic representation:

[0143] Figure 1 shows a mold of an apparatus for injection molding according to the present invention.

[0144] In the diagram, the same component symbol is used to represent the same component or components with the same function. Implementation

[0145] The mold 1 includes a first mold half 2 and a second mold half 3, which can be separated from each other through the mold separation plane E.

[0146] The technical design of mold 1 determines the number of mold parts required and the number of mold separation planes. Necessary guides, through-hole tapers and ejector bolts, cooling and / or heating medium supply, electronic assembly for a heating element, deburr, and cutting tools for cutting off the filling channel are not shown in the figure.

[0147] The mold 1 may include a first insert 5 and a second insert 5'. According to the present invention, inserts 5 and 5' comprise a polymer.

[0148] A detection window 4 is shown in the second mold half 3, which separates the second mold half 3 from an injection molding space 10 and the insert 5', specifically by a pressure sealing method. Specifically, the alignment mark 5m' of the insert 5', which has an alignment device (not shown), can be observed through the detection window 4 and adjusted by the positioning mechanism 6.

[0149] The pressure distributor 7 allows the detection window 4 and / or the side behind the insert 5b' to be covered with the alignment mark 5m' during injection molding, so that the operating pressure is maintained at up to (e.g.) 2500 bar during injection molding, while the injection molding compound (not shown) cannot escape from the mold 1, specifically in an uncontrolled manner.

[0150] Inserts 5 and 5' are positioned in the mold 1 in a alignable and adjustable manner with the structured molding surfaces 5s and 5s', specifically in the direction of the injection molding space 10 in the mold halves 2 and 3.

[0151] Inserts 5 and 5' may include alignment marks 5m and 5m' specifically configured as a cluster of marks, which are located both on the structured molding surfaces 5s and 5s' and on the rear side of inserts 5b and 5b', so as to enable reference or association between the molding surfaces 5s and 5s' of inserts 5 and 5' and the rear side 5b and 5b' of inserts 5 and 5'. Measurements are not necessarily performed in mold 1.

[0152] In a particularly preferred embodiment not shown, the rear sides 5b, 5b' of inserts 5, 5' may be processed to achieve flatness requirements, wherein the molded surfaces 5s, 5s' of inserts 5, 5' may be used in a structured manner. In certain cases, the molded surfaces 5s, 5s' of inserts 5, 5' may exist without structured processing, without considering the processing or processability of the rear sides 5b, 5b' of inserts 5, 5'.

[0153] The mold 1 is filled with an injection molding compound (not shown) in the filling opening 8, so that it enters the injection molding space 10 and, specifically, completely fills the cavity of the injection molding space 10. In order to completely fill the injection molding space 10 of the mold 1 without air bubbles, voids or inclusions, specifically, a vent 9 is formed in the mold 1.

[0154] An insert 5 without a detection window is symbolically depicted in the first mold half 2. Corresponding channels are formed in the mold 1 to allow optical observation of the rear side 5b of the specific insert 5 and to align the inserts 5 and 5' with each other. In this embodiment, a pressure distributor 7 supports the inserts 5 and 5' to protect them from breakage due to overload of the injection molding compound.

[0155] The overload of inserts 5 and 5' may include a thermal overload and a mechanical overload, which can be prevented by unrestrained clamping and a specific full-area support of inserts 5 and 5' in mold 1.

[0156] 1: Molds used for injection molding 2: First mold half 3: Second mold half 4: Detection window 5: Inserts 5': Insert 5s: Structured molded surface of inserts 5s': Structured molded surface of inserts 5b: Back side of insert 5b': Insert rear side 5m: Alignment mark for insert 5m': Alignment mark for insert 6: Positioning mechanism 7: Pressure distributor 8: Fill the opening 9: Ventilation tube 10: Injection Molding Space E: Mold separation plane

Claims

1. An apparatus for injection molding, comprising at least: A mold (1) having a first mold half (2) and a second mold half (3), wherein the first mold half (2) and the second mold half (3) define an injection molding space (10) in a closed state of the mold (1), and at least one insert (5) disposed in the injection molding space (10), characterized in that the at least one insert (5) at least partially comprises a polymer, wherein the device further comprises at least one further insert (5') disposed in the injection molding space (10), wherein the at least one insert (5) and / or the at least one further insert (5') are alignable in the closed state of the mold (1), and wherein the at least one insert comprises a structured surface produced by imprint lithography.

2. The apparatus of claim 1, wherein the at least one insert (5) and / or the at least one further insert (5') includes a molded surface (5s, 5s') having an elastic structure.

3. The apparatus of claim 2, wherein the molded surface (5s) of the at least one insert (5) and the molded surface (5s') of the at least one further insert (5') are aligned with each other in the closed state of the mold (1).

4. The apparatus of claim 2, wherein the elastic structures of the molding surface (5s) of the at least one insert (5) and the elastic structures of the molding surface (5s') of the at least one further insert (5') are aligned with each other in the closed state of the mold (1).

5. The apparatus of claim 2, wherein at least one heating element is integrated in the at least one insert (5), the at least one further insert (5') and / or the respective resilient structures, such that the injection molding space (10), wherein an injection molding compound that can be delivered to the injection molding space (10) through a filling opening (8) can be heated in a calibrated manner by the at least one heating element.

6. The apparatus of claim 1, wherein the at least one insert (5) and / or the at least one further insert (5') includes a plurality of alignment marks (5m, 5m') on their respective molded surfaces (5s, 5s') and / or on their respective rear sides (5b, 5b').

7. The apparatus of claim 6, wherein the first mold half (2) and / or the second mold half (3) includes a detection window (4) such that the at least one insert (5) and / or the at least one further insert (5') can be aligned with each other in the closed state of the mold (1) by means of the plurality of alignment marks (5m, 5m').

8. The apparatus of claim 6, wherein at least one of the first mold half (2) and the second mold half (3) includes at least one positioning mechanism (6) such that the at least one insert (5) and / or the at least one further insert (5') can be aligned in the closed state of the mold (1) by means of the plurality of alignment marks (5m, 5m').

9. The apparatus of claim 2, wherein the elastic structures of the molded surface (5s) of the at least one insert (5) and / or the molded surface (5s') of the at least one further insert (5') can be aligned with each other in the closed state of the mold (1) by means of a plurality of alignment marks (5m, 5m') on the rear side (5b) of one of the at least one insert (5) and / or the rear side (5b') of one of the at least one further insert (5').

10. A method for injection molding, comprising: An injection molding space (10) is defined in a closed state of a mold (1) having a first mold half (2) and a second mold half (3). A structured surface of at least one insert (5) is produced by imprinting. The at least one insert (5) and at least one further insert (5') are disposed in the injection molding space (10), wherein the at least one insert (5) and / or the at least one further insert (5') are alignable in the closed state of the mold (1). The at least one insert (5) disposed in the injection molding space (10) comprises at least a polymer.

11. The method of claim 10, wherein one molded surface (5s) of the at least one insert (5) and / or one molded surface (5s') of the at least one further insert (5') are aligned with each other in the injection molding space (10) in the closed state of the mold (1).

12. The method of claim 10, wherein the at least one insert (5) and / or the at least one further insert (5') are aligned by means of a plurality of alignment marks (5m, 5m') disposed on the at least one insert (5) and / or the at least one further insert (5').

13. The method of claim 10, wherein the alignment of one of the at least one insert (5) and / or the at least one further insert (5') is performed based on a measurement of one of the injection-molded articles produced according to the method of claim 10.

14. The method of claim 10, wherein an alignment is achieved by reprocessing one of the at least one insert (5) and / or the at least one further insert (5').

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