Timepiece Component Manufacturing via Polymer Mould Electroforming
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Solution Overview
Problem
Current methods for manufacturing timepiece components, such as UV-LIGA and polymer replication, face challenges including high costs, long processing times, limited ability to produce complex 3D parts, and poor surface texture replication, especially with directional photolithography and high fluidity polymer requirements.
Innovation Solution
A method involving the creation of a high-precision polymer mould using a master piece, where a fluid resin is applied and pressed onto the master, followed by electroforming or electroless plating to build the component, allowing for efficient production of multi-level components with free forms and surface textures, while minimizing moulded-in stress and achieving high replication fidelity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV-LIGA technology is used to manufacture timepiece components, then manufacturing precision and surface texture replication are improved, but processing time and production cost increase significantly
Solution Approach 1:
The patent uses a master model to create a polymeric mould that copies the desired surface topology, then uses this mould to replicate multiple components. This copying approach allows high-fidelity surface texture replication without repeating the complex UV-LIGA photolithography process for each component, significantly reducing processing time while maintaining manufacturing precision.
Solution Approach 2:
The master model and polymeric mould are prepared in advance before component production. The mould is created once and then used for high-volume replication of multiple components. This preliminary action eliminates the need to perform time-consuming photolithography steps for each individual component, reducing overall processing time while preserving surface texture fidelity.
2Ease of manufacture
If compression moulding or hot embossing is used for polymer replication, then manufacturing simplicity is improved, but thickness control and edge definition deteriorate
Solution Approach 1:
The patent changes the temperature parameter during the compression moulding process. The master model and mould are heated to a temperature above the glass transition temperature of the polymer, increasing polymer fluidity for better surface replication, then cooled below the glass transition temperature to solidify the replicated features. This parameter change enables both simple manufacturing and high precision thickness control with well-defined edges.
3Productivity
If injection moulding is used to manufacture timepiece components, then productivity and volume production are improved, but surface texture replication fidelity and stress control worsen
Solution Approach 1:
The patent changes the temperature parameter to control polymer fluidity during injection moulding. By heating the master model and mould above the glass transition temperature, the polymer achieves optimal fluidity for filling the mould cavity in high-volume production, then cooling below the glass transition temperature solidifies the polymer with minimal shrinkage and stress. This parameter control enables both high productivity and high surface texture replication fidelity.
Solution Approach 2:
The patent utilizes the phase transition of the polymer at its glass transition temperature. The master model and mould are heated above this temperature during injection to ensure complete cavity filling with high surface fidelity, then cooled below this temperature to solidify the replicated features with minimal deformation and stress. This phase transition approach enables high-volume production while maintaining surface reproduction quality.
4Shape
If photolithography is used for LIGA mould fabrication, then in-plane complex shapes are achieved, but 3D multilevel structure capability and production cost are limited
Solution Approach 1:
The patent transitions from 2D photolithography to 3D surface replication by using a master model with three-dimensional surface topology. The polymeric mould captures the full 3D shape including height, width, and depth information, enabling fabrication of complex 3D multilevel structures without being restricted to successive in-plan shapes. This dimensional change provides versatility for creating free-form 3D components with integrated surface decorations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the efficient and cost-effective production of timepiece components with precise replication of complex shapes and surface textures, achieving high fabrication tolerances and low residual stress, similar to UV-LIGA processes, while allowing for high-volume replication and controlled chamfered edges.
Implementation Method 1
a fluid resin is applied onto the master. The master is placed on a fixed support, and after the fluid resin has been applied on to the master, the resin is pressed onto the master by means of a press
Implementation Method 2
the resin is pressed onto the master by means of a press
Implementation Method 3
the resin is pressed onto the master by means of a press... resulting polymer moulds have low residual or moulded-in stress and high strength, and therefore deformations of the polymer mould are greatly minimised during their release
Implementation Method 4
The mould is then filled with a metallic material (e.g., by electroforming or electroless plating) such as to build up the timepiece component with the material
Implementation Method 5
The Mould is then filled with a metallic material (e.g., by electroforming or electroless plating)
Data Source
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AI summary
A method for manufacturing a timepiece component comprising the steps of manufacturing a master for the timepiece component and then manufacturing a polymer mould based on the master piece. The mould is then filled with a metallic material (e.g., by electroforming or electroless plating) such as to build up the timepiece component with the material, and the component is then separated from the mould. According to the invention, during the step of manufacturing the mould, a fluid resin is applied onto the master. Preferably, the master is placed on a fixed support, and after the fluid resin has been applied on to the master, the resin is pressed onto the master by means of a press. The step of filling the mould with the metallic material may be preceded by a step of at least partly coating the mould with a conductive or catalytic coating. The invention also relates to a timepiece component manufactured by means of the above method. The timepiece component may comprise a surface topology or pattern on the nanometer and/or micrometer scale that is faithfully replicated from the master.