Mold Recessed Step Pattern Production via Inversion
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Solution Overview
Problem
Existing methods for producing molds with recessed patterns in recessed step portions often result in steep steps and gaps, leading to adverse effects on electroforming and molding processes, and lack configurations to prevent liquid material from flowing, causing instability in the shape of the recessed step portion.
Innovation Solution
A production method involving a plate precursor with a pedestal and a thermoplastic resin plate with a recessed step portion of equal or lesser volume, where the protruding pattern is pressed against the recessed step to form an inverted pattern, ensuring the resin is pushed outside the step, thereby preventing flow and stabilizing the shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flat surface of the mold is pressed against the thermoplastic resin plate to transfer the pattern, then the pattern is transferred successfully, but a steep step is formed at the end portion of the raised resin which adversely affects subsequent electroforming and molding
Solution Approach 1:
The invention inverts the traditional approach by forming the recessed pattern directly in the recessed step portion rather than forming a protruding pattern on a flat surface. This inversion allows the resin to be pushed outside the step portion during pressing, eliminating the steep step problem while maintaining pattern transfer precision.
Solution Approach 2:
The invention applies different functional qualities to different regions: the recessed step portion serves as a containment structure with specific volume, while the recessed pattern formed within it provides the functional pattern. This local differentiation ensures that the resin displacement is contained and directed properly, preventing steep step formation.
2Stability of the object's composition
If a recessed step is provided in the periphery of the inverted pattern of the thermoplastic resin plate precursor, then the resin is contained, but a gap is formed between the end portion of the raised resin and the recessed step which adversely affects electroforming and molding
Solution Approach 1:
The invention performs preliminary action by pre-forming the recessed step portion with a specifically controlled volume before pattern transfer. This preliminary structure ensures that during the pressing operation, the resin is contained and pushed outside the step portion, preventing gap formation between the resin end portion and the step.
3Manufacturing precision
If the recessed pattern is formed at the bottom surface of the recessed step portion without considering the size of the recessed step portion, then the pattern is formed, but the shape of the recessed step portion becomes unstable and adversely affects subsequent electroforming and molding
Solution Approach 1:
The invention changes the critical parameter of recessed step portion volume to be equal to or less than the total volume of the protruding pattern and pedestal. This parameter control ensures that during pressing, the resin is contained within the step portion and pushed outside, maintaining shape stability while enabling proper pattern formation at the bottom surface.
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 minimizes failures in electroform and mold production by forming a stable recessed pattern that prevents liquid flow, ensuring a flat bottom surface and reducing defects in subsequent processes.
Implementation Method 1
a recessed pattern forming step of forming a recessed pattern having an inverted shape of the protruding pattern on the thermoplastic resin plate by pressing the protruding pattern of the heated plate precursor and the pedestal against the bottom surface of the recessed step portion
Data Source
AI summary
A production method of a mold having a recessed pattern includes: a plate precursor preparation step of preparing a plate precursor having a pedestal on which a protruding pattern is disposed; a resin plate preparation step of preparing a thermoplastic resin plate having a recessed step portion; and a resin plate precursor production step of producing a thermoplastic resin plate precursor. The plate precursor comprises a substrate having a larger area than the pedestal in a plan view on a side opposite to a surface of the pedestal on which the protruding pattern is disposed. An edge portion where a side surface of the pedestal and the substrate are in contact with each other has a through-hole penetrating the substrate along the side surface of the pedestal.