Photosensitive Resin Mold Exposure for Vertical Electroplating Edges
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Solution Overview
Problem
Existing methods for manufacturing electroplating or metal growth molds for watch and jewelry components face limitations in flexibility, precision, and cost due to the need for a new mask for each component and inefficiencies in irradiating photosensitive resin, leading to geometry deviations in the final product.
Innovation Solution
A method involving multiple sequential irradiations with adjustable irradiation characteristics, such as focus, energy, and wavelength, to precisely form impressions in photosensitive resin without a physical mask, allowing for flexible and cost-effective production of molds with high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mask is used to irradiate photosensitive resin, then the mold can be manufactured, but the manufacturing flexibility is limited and production costs increase due to the need for a new mask for each component
Solution Approach 1:
The patent removes the physical mask from the system entirely, replacing it with direct digital irradiation of the photosensitive resin. This extraction eliminates the need for mask manufacturing, storage, and changeover, thereby improving manufacturing flexibility while reducing device complexity related to mask handling.
Solution Approach 2:
The patent uses digital patterns projected onto the photosensitive resin as virtual copies of the desired mold geometry, replacing physical masks. This allows instant changes between different component designs without manufacturing new physical masks, enhancing adaptability while reducing the complexity of mask management.
2Manufacturing precision
If a single irradiation dose is applied to photosensitive resin, then the process is fast, but the edges of impressions do not conform to desired geometry due to diffraction, reflection, and absorption phenomena
Solution Approach 1:
The patent divides the irradiation process into multiple sequential doses applied at different focal depths. The first dose irradiates the upper portion of the resin, while the second dose irradiates the lower portion. This segmentation allows precise control over edge geometry at each depth level, achieving vertical edges without sacrificing overall process efficiency.
Solution Approach 2:
The patent applies different irradiation characteristics (focus, energy, wavelength) to different depth zones within the photosensitive resin. By tailoring the irradiation parameters locally to each depth region, the process achieves precise edge geometry control while maintaining reasonable productivity through optimized parameter selection.
3Manufacturing precision
If multiple sequential irradiations with parameter adjustments are used, then precise vertical edges are achieved, but the irradiation process time increases
Solution Approach 1:
The patent changes irradiation parameters (focus position, energy, wavelength) between doses to optimize the process. By adjusting these parameters, the system achieves precise vertical edges while minimizing the time penalty of multiple irradiations through efficient parameter optimization.
Solution Approach 2:
The patent uses periodic irradiation with alternating focus positions - first focusing on the upper resin layer, then on the lower layer. This periodic action pattern allows systematic control of edge verticality while maintaining a reasonable total processing time through optimized cycle design.
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 the production of molds with precise vertical edges and reduced production time, eliminating the need for a new mask for each component, thereby enhancing flexibility and reducing costs while maintaining high precision.
Implementation Method 1
irradiate a first portion of the photosensitive resin to deliver a first dose of predetermined irradiation energy... deliver a second dose of predetermined irradiation energy
Data Source
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AI summary
The invention relates to a method for manufacturing a mold (10) for electroplating or metal growth of a watch part (31, 32) or a piece of jewelry (31, 32), comprising the steps of: - obtaining a base substrate (11), - depositing at least one layer of photosensitive resin (13), - irradiating the photosensitive resin (13) to deliver a first dose of predetermined irradiation energy to a first depth (P1) in the photosensitive resin (13), characterized in that the irradiation step includes, after irradiating the first portion of the photosensitive resin (13), an adjustment and/or a modification of an irradiation characteristic, to deliver a second dose of predetermined irradiation energy to a second depth (P2) in the photosensitive resin (13).