Mask-Free Irradiation for Precision Electroplating Molds
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Solution Overview
Problem
Existing methods for manufacturing electroplating or metal growth molds for watch and jewelry components are inflexible, costly, and result in imperfect geometry due to the use of masks and time-consuming irradiation techniques, leading to deviations in perpendicularity and flatness.
Innovation Solution
A method that irradiates photosensitive resin without a physical mask, using a single pass for large surface areas and adjustable irradiation patterns, allowing for flexible and precise mold manufacturing without additional costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a physical mask is used to irradiate photosensitive resin, then the irradiation pattern can be defined, but the manufacturing flexibility decreases and production costs increase due to mask manufacturing and replacement requirements
Solution Approach 1:
The patent extracts and eliminates the physical mask from the irradiation system, using direct digital projection of patterns onto the photosensitive resin. This removes the constraint of mask manufacturing and replacement while maintaining pattern definition capability through digital means.
Solution Approach 2:
The patent uses digital copies of design patterns projected through optical systems onto the photosensitive resin, replacing physical masks with virtual pattern projections. This allows instant pattern changes without physical mask replacement.
2Manufacturing precision
If a physical mask is used for irradiation, then pattern definition is achieved, but the device complexity and additional manufacturing costs increase
Solution Approach 1:
The physical mask component is completely removed from the system, replacing it with a digital pattern generation and projection system. This reduces device complexity by eliminating mask manufacturing, storage, and handling infrastructure.
Solution Approach 2:
The mechanical mask system is replaced with an optical-digital projection system that uses light modulation and digital pattern generation to achieve the same pattern definition function without physical masks.
3Adaptability or versatility
If laser beam or electron beam is used to irradiate photosensitive resin, then irradiation can be performed without masks, but the irradiation time increases significantly
Solution Approach 1:
The irradiation process is segmented into multiple parallel projection zones, allowing different portions of the photosensitive resin to be irradiated simultaneously by dividing the projection field into multiple active regions that can be activated in parallel.
Solution Approach 2:
The patent transitions from one-dimensional beam scanning to two-dimensional parallel projection, irradiating large surface areas simultaneously by projecting patterns across the entire resin surface rather than scanning point-by-point.
4Productivity
If conventional irradiation methods are used, then irradiation can be performed, but the edges of impressions do not conform to desired geometry resulting in deviations in perpendicularity and flatness
Solution Approach 1:
The projection system uses dynamic focus adjustment and real-time optical parameter modification during irradiation to maintain precise edge definition and geometric accuracy across the entire resin surface, compensating for depth variations and optical distortions.
Solution Approach 2:
The patent modifies optical parameters such as wavelength, focus distance, and projection angle during the irradiation process to optimize edge sharpness and geometric fidelity, ensuring that impression edges accurately conform to the desired pattern geometry.
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
Enables fast, flexible, and precise manufacturing of electroplating or metal growth molds with improved geometry, reducing production costs and ensuring high precision in watch and jewelry components.
Implementation Method 1
irradiate photosensitive resin with a laser beam or an electron beam... once the photosensitive resin has been irradiated, it can be developed in a specific developing solvent, thus forming impressions and edges within the resin
Data Source
Figure 1~4
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Figure 9~12
AI summary
The invention relates to a method for manufacturing a mold for electroplating or metal growth of a watch part (31, 32) or a piece of jewelry (31, 32), comprising the steps of: - obtaining at least one base substrate (11), - depositing at least one layer of photosensitive resin (13), - irradiating at least a first portion of the layer of photosensitive resin (13) - characterized: - in that the irradiation of the first portion of said at least one layer of photosensitive resin (13) comprises a step of projecting onto said at least one layer of photosensitive resin (13) at least one first irradiation pattern (PM) corresponding to at least a first portion of a first watch or jewelry part (31, 32).