JP2002240043A - Mold manufacturing method, replica master and mold - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve such a problem that a mold having a molding surface with a complicated shape or a thin wall of a mm unit and having a dimensional shape of high accuracy as a whole cannot be easily manufactured heretofore. SOLUTION: A first matrix 11a having a molding surface 12a of high accuracy, second materials 11b and 11c having molding surfaces 12b and 12c lower in accuracy than the molding surface 12a, and a dummy mold 15 having the dummy molding surface 17 connected to the molding surfaces 12b and 12c of the second matrices 11b and 11c, are prepared. The first and second matrices 11a-11c and the dummy mold 15 are integrally connected, and the molding surfaces 12a-12c and 17 of them are coated with an optically reactive curable resin 19 to be irradiated with light to previously cure the part of the optically reactive curable resin 19 facing to the molding surface 12a of the first matrix 11a. Subsequently, the parts of the optically reactive curable resin 19 facing to the molding surfaces 12b and 12c of the second matrices 11b and 11c and the dummy molding surface 17 of the dummy mold 15 are cured, and the cured optically reactive curable resin 19 is demolded as a replica master 21.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a mold having a molding surface having the same shape as a mother mold using a replica master having a shape corresponding to the molding surface of the mother mold, and a replica master produced by the method. And mold.

[0002]

2. Description of the Related Art In general, when a large number of optical components such as small-diameter aspherical lenses, microlenses, lens arrays, and diffraction gratings, and components requiring precise dimensions and shapes are manufactured in large quantities, a manufacturing method by molding is used. Adopted. For example, a mold for injection molding an ink jet print head generally uses iron, copper, aluminum and their alloys as a base material, and forms a thick electroless plating layer on the surface thereof.
It is manufactured by cutting this electroless plating layer into a desired shape with a diamond tool. As another processing method of a mold having a molding surface of a minute shape, a method by electric discharge machining using a large number of electrodes is also known, but parts manufactured by these manufacturing methods are very expensive. Have a tendency to be

In recent years, resin products have been made into a single part with the progress of molding technology, and thus have many functions. Molds are often provided with a molding surface having a complicated and fine shape that requires extremely high-precision dimensional control. For example, FIG. 9 shows a cross-sectional structure of a main part of a mold for injection-molding the above-described inkjet print head.
FIG. 11 shows the appearance of a forming piece for forming a common liquid chamber, and FIG. 10 shows the appearance of a forming piece for forming a liquid path in a broken state. That is, a molding piece 3 forming a cavity 4 serving as a liquid path between the molding piece 3 forming a cavity 1 serving as a common liquid chamber and the upper mold 2 is disposed adjacently. ing. When the interval between the liquid paths of the inkjet print head is 360 dpi, the molding surface 5 of the molding piece 4 that forms the cavity 4 serving as the liquid path includes:
It is necessary to form corresponding tooth spaces at intervals of 70.5 μm. Conventionally, tooth spaces are formed by cutting because of the required accuracy. On the other hand, the molding surface 6 of the molding piece 3 for forming the cavity 1 serving as the common liquid chamber is conventionally formed by electric discharge machining in order to realize a three-dimensional shape required for functional design as an ink jet print head. .

When these two molding pieces 3 and 4 are integrated as a lower mold, a step is not formed between the cavity 1 formed by the molding piece 3 and the cavity 4 formed by the molding piece 4. Therefore, not only the processing accuracy of the molding pieces 3 and 4 but also the assembly accuracy, the incorporation technology, the measurement technology and the like are required. However, in the initial state of the actual injection molding operation, even if the above-mentioned step does not occur, the relative position of the two molding pieces 3 and 4 is slightly affected by the injection pressure during continuous operation. A gap is coming.

[0005] The necessity of increasing the accuracy of assembling the mold and re-adjusting the position of the mold during the continuous molding operation is not limited to the mold for molding the ink jet print head described above. It may occur in a product having another fine shape requiring a complicated molding surface and high dimensional accuracy, or a mold for molding an optical component.

In order to prevent such a problem, a plurality of molding pieces are manufactured in advance as one molding piece. However, these are manufactured as one forming piece by machining while maintaining desired dimensional accuracy. That is extremely difficult at present. Therefore, a replica method using an ultraviolet curable resin has been proposed in Japanese Patent Application Laid-Open No. Hei 3-202486. In the method disclosed in Japanese Patent Application Laid-Open No. Hei 3-202486, a mother die is manufactured by using an electron beam, and an electroforming process is performed using the mother die to manufacture a first metal mold. A replica master made of an ultraviolet curable resin is manufactured using the first mold, and an electroforming process is performed using the replica master to manufacture a second mold.

However, since the ultraviolet curable resin undergoes volume shrinkage when it is cured, some contrivance is required to obtain high dimensional accuracy. For example, Japanese Unexamined Patent Publication
JP-A-59104 proposes a method of improving the transferability of a molding surface by controlling the region of the ultraviolet-cured resin applied to the mold to be irradiated with ultraviolet rays by using a mask. Japanese Patent Application Laid-Open No. 1-171932 discloses a method in which a transfer operation is repeated a plurality of times on a molding surface of a matrix to improve the transferability of an ultraviolet curable resin serving as a replica master on the molding surface. Proposed.

[0008]

Problems to be Solved by the Invention
In the method disclosed in Japanese Patent Publication No. 6, when the ultraviolet curable resin is cured, it causes volume shrinkage, so that it is extremely difficult to manufacture a replica master for electroforming with high precision. In particular, in the case of a mold having a fine molding surface such that the thickness of the portion constituting the molding surface is in the order of mm, it becomes increasingly difficult to manufacture the mold.

In the method disclosed in Japanese Patent Application Laid-Open No. 6-59104, the method of controlling the irradiation area of ultraviolet rays as shown in FIG. 4 requires a special device for controlling the irradiation area. There was also a problem that the control conditions had to be set by trial and error.

In the method disclosed in Japanese Patent Application Laid-Open No. 1-171932, the transfer operation is repeated a plurality of times to improve the transferability of the ultraviolet-curable resin serving as the replica master. Although the dimensional accuracy of the replica master is gradually improved, the processing time is increased in accordance with the repetition of the transfer operation, resulting in a problem that the manufacturing cost of the replica master is increased. Also, in this method, for a matrix having a molding surface with a complicated shape,
Due to the repetition of the transfer operation, it becomes increasingly difficult to repeatedly supply the resin to the details of the complicated molding surface, and it is also difficult to manufacture a highly accurate replica master.

[0011]

An object of the present invention is to provide a molding surface having a complicated shape or the like.
It is an object of the present invention to provide a method capable of easily manufacturing a mold having a high-precision dimension having a thin portion in a unit of mm, and a replica master and a mold manufactured by the method.

[0012]

According to a first aspect of the present invention, there is provided:
A method of manufacturing a mold having a molding surface having the same shape as the master using a replica master having a transfer surface having a shape corresponding to the molding surface of the mother, wherein a high-precision molding surface is used as the master. A first mold having at least one second mold having a molding surface having a lower precision than a molding surface of the first mold.
Preparing a mold having a dummy molding surface connected to at least the molding surface of the second mother mold; and forming a molding surface of the first and second mother molds, So that the dummy molding surface of the dummy mold is continuous
Integrally connecting the first and second master molds and the dummy mold; and integrating the first and second molds with each other.
Covering the molding surface of the master mold and the dummy molding surface of the dummy mold with a photoreactive curable resin, and irradiating the photoreactive curable resin with light to face the molding surface of the first master mold. Following the step of curing the photoreactive curable resin portion and the curing of the photoreactive curable resin facing the molding surface of the first mother die, the formation surface of the second mother die and the dummy mold Curing the portion of the photoreactive curable resin facing the dummy molding surface; and stamping out the photoreactive curable resin cured from the first and second mother dies and the dummy mold as a replica master. It is characterized by having.

[0013] In the present invention, the photoreactive curable resin portion facing the highly accurate molding surface of the first mother die is cured first, and then the molding surface of the second mother die and the dummy molding surface of the dummy mold are formed. By curing the exposed portion of the photoreactive curable resin, an adverse effect due to curing shrinkage of the photoreactive curable resin is prevented from appearing on the highly accurate molding surface of the first mother die.

According to a second aspect of the present invention, there is provided a replica master manufactured by the mold manufacturing method according to the first aspect of the present invention.

According to a third aspect of the present invention, there is provided a step of performing electroforming on the photoreactive cured resin that has been cut out, a step of machining the electroformed mold material as a mold, and a step of machining. Removing the photoreactive curable resin from the processed mold. The mold according to the first aspect of the invention, further comprising:

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In a mold manufacturing method according to a first embodiment of the present invention, before the step of curing a photo-reactive curable resin, the molding surfaces of the first and second mother dies and the dummy of the dummy mold are formed. The method may further include a step of defoaming from the photoreactive curable resin coated on the molding surface, and in this case, the step of defoaming from the photoreactive curable resin is preferably performed in a vacuum atmosphere. .

[0017] The method further comprises the step of integrally joining the release plate to the photoreactive curable resin, and the step of removing the photoreactive curable resin from the first and second mother dies and the dummy mold comprises releasing the knock pin. First and second against the template
May be separated from the master mold and the dummy mold.

Aluminum is vacuum-deposited on the molding surface of the first mother die, or the surface roughness value of the molding surface of the first mother die is changed to the molding surface of the second mother die and the dummy molding surface of the dummy mold. Is set smaller than the value of the surface roughness of the first mother die, the light reflectance of the molding surface of the first mother die is set higher than the light reflectance of the molding surface of the second mother die and the dummy molding surface of the dummy mold. Is preferred. Further, by making the surface roughness value of the molding surface of the second matrix smaller than the surface roughness value of the dummy molding surface of the dummy mold, the light reflectance of the molding surface of the second matrix can be reduced. It is preferable to set higher than the light reflectance of the dummy molding surface of the mold.

The photoreactive curable resin may be a radical polymerization type ultraviolet curable resin.

Electroforming the molded photoreactive curable resin; machining the electroformed mold material as a mold; and performing photoreactive curing from the machined mold. And a step of removing the resin.

According to the present invention, the initial curing method of the radical polymerization type ultraviolet curable resin supplied to the transfer surface is generally to cure slowly with low energy ultraviolet rays in order to improve transferability. In the case of a thin material such as a sheet, polymerization is inhibited by oxygen and the vicinity of the surface in contact with oxygen in the air is not cured, but is cured from the inside. However, if the thickness is in the order of millimeters, the photoinitiator near the surface reacts strongly when it is performed in the same manner, and cures faster than the resin near the shape transfer surface below.

[0022] Therefore, with the curing shrinkage of the upper resin,
The resin in the vicinity of the shape transfer surface is released from the mold, which lowers the transfer accuracy. Therefore, the difference in the surface roughness of each piece, or vacuum evaporation of aluminum on some pieces, to improve the reflectance of ultraviolet near the center of the entire transfer surface,
Preventing the resin near the transfer surface from releasing from the mold by making the curing speed of the resin by reflected light faster than the surrounding area,
In order to make the influence of curing shrinkage difficult to appear on the shape transfer surface,
A reduction in transfer accuracy was prevented.

[0023]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a mold manufacturing method according to an embodiment of the present invention; however, the present invention is not limited to such an embodiment. The present invention can be applied to other technologies that should be included in the concept of the present invention described in the range described above.

The matrix in the present embodiment is composed of machine-formed three-part matrixes 11a, 11b and 11c, each having a sectional shape as shown in FIG. The first mother die 11a is formed with a highly precise molding surface 12a having a narrow concave portion or a complicated shape that becomes a thin portion in a unit of mm in a molded product by electric discharge machining, cutting, or the like. In addition, the second matrix 1 sandwiching the first matrix 11a
Molding surfaces 12b and 12c having lower accuracy than the molding surface 12a of the first master block 11a are formed on the first and second molds 1b and 11c, respectively. Matrices 11a to 11c and molding surfaces 12a to 12c
Can be changed to any shape other than the present embodiment according to the shape and size of the target molded product, and only one of the second mother dies 11b and 11c is used. In some cases.

In the present embodiment, the molding surface 12a of the first matrix 11a is a metal reflection film 1 for improving light reflectance.
3. The metal reflection film 13 is formed of a thin film of, for example, aluminum. The metal reflection film 13 can be formed by using vacuum evaporation or sputtering, and preferably has a thickness of 1 μm or less. As means for improving the light reflectance, the value of the surface roughness of the molding surface 12a is reduced,
That is, it is also possible to cope with the mirror surface. Further, the molding surface 12 of the second matrixes 11b and 11c in the present embodiment.
For b and 12c, the value of the surface roughness is set to be smaller than that of a dummy molding surface of a dummy mold described later.

Next, a matrix unit 14 as shown in FIG. 2 in which the matrixes 11a to 11c were combined was assembled. The master unit 14 in the present embodiment is the same as the master 11a described above.
11c and a dummy mold 15 connected to the second mother dies 11b and 11c so as to surround the mother dies 11a to 11c.
A connecting plate 16 for integrally connecting the mother dies 11a to 11c and the dummy mold 15 is provided.
A dummy molding surface 17 connected to the molding surfaces 12b and 12c of the mother dies 11b and 11c is formed. Three or more (four in this embodiment) knock pins 18 slidably pass through the dummy die 15 and the connecting plate 16 in parallel with each other, and the lower ends thereof are connected to a pin elevating means (not shown) to form a dummy. It can move up and down with respect to the mold 15 and the connecting plate 16. The dummy molding surface 17 has at least the second matrix 1.
The portions connected to the molding surfaces 12b and 12c of 1b and 11c are set so as to be flush with them.
The surface roughness having a larger value than the molding surfaces 12b, 12c of the second mother dies 11b, 11c so as to have a light reflectance lower than that of the molding surfaces 12b, 12c of the second mother dies 11b, 11c. Is set to

When only one second mother die 11b, 11c is used, the dummy molding surface 17 of the dummy mold 15 is flush with the molding surface 12a of the first mother die 11a at a portion connected to the molding surface 12a. Is also set. The main part of the matrix unit 14 in the present embodiment is standardized in terms of their dimensions and shape, and can be adapted to various types of molds simply by changing a few components.

The molding surface 12 of such a matrix unit 14
a to 12c and the dummy molding surface 17 are immersed in isopropyl alcohol and subjected to ultrasonic cleaning.
In order to improve the releasability of an ultraviolet-curable resin, which will be described later, with respect to a to 12c and the dummy molding surface 17, an organosilane diluted with isopropyl alcohol is used in the master unit 1
4 was immersed in the molding surfaces 12a to 12c and the dummy molding surface 17.

As shown in FIG. 3, the liquid surface of the urethane acrylate-based ultraviolet curable resin 19 as the photoreactive curable resin according to the present invention is adjusted so that it does not overflow from the molding surfaces 12a to 12c and the dummy molding surface 17. After supplying the liquid to such an extent that it is raised by tension, vacuum defoaming is performed to confirm with a microscope or the like that the ultraviolet curable resin 19 is in close contact with the molding surfaces 12a to 12c and the dummy molding surface 17. In this way, the ultraviolet curable resin 19 is
The vacuum defoaming process is repeated until it can be confirmed that 2a to 12c and the dummy molding surface 17 are completely adhered.

Next, in order to prevent the flat release plate 20 made of transparent glass from coming into contact with the mother dies 11a to 11c and the dummy die 15, the outer edge of the release plate 20 is formed on the molding surface 12a of the mother die unit 14. To 12c and the upper ends of the plurality of knock pins 18 protruding from the dummy molding surface 17,
By operating the pin elevating means, the knock pin 18 is lowered, and the lower surface of the release plate 20 is brought into close contact with the surface of the ultraviolet curable resin 19. The lower surface of the release plate 20 is preliminarily subjected to a silane treatment with a silane coupling agent as a pretreatment so that the ultraviolet effect resin 19 and the lower surface of the release plate 20 are integrally joined to each other. It has become.

Thereafter, an ultraviolet ray having an illuminance of 0.5 mW / cm ² was irradiated to the ultraviolet curable resin 19 through the release plate 20 for 20 minutes, and after pre-curing, the illuminance was further increased to 10 mW / c.
The ultraviolet curable resin 19 was completely cured by irradiating ultraviolet rays of m ² for 5 minutes. In this case, the reflectance of ultraviolet light on the molding surface 12a is reduced by the metal reflection film 13 constituting the molding surface 12a of the first matrix 11a.
Since the molding surfaces 12b and 12c of the first mold 11a and the dummy molding surface 17 of the dummy mold 15 are higher than the molding surfaces 12b and 12c of the dummy mold 15, the curing in the region of the ultraviolet curing resin 19 facing the molding surface 12a of the first mother die 11a is prevented. This occurs earlier, and since the release plate 20 is placed on the ultraviolet curable resin 19 and its outer peripheral edge is in a released state, the uncured ultraviolet curable resin 19 is in its central part, that is, Matrices 11a to 11c
Shrinks toward the molding surfaces 12a to 12c of the base mold 11a.
The curing proceeds while the ultraviolet curing resin 19 is in close contact with the molding surfaces 12a to 12c of the molding surfaces 11a to 11c. further,
The surface roughness values of the molding surfaces 12b, 12c of the second mother dies 11b, 11c are set to be smaller than those of the dummy molding surface 17 of the dummy mold 15, and the reflectance of the ultraviolet rays on these molding surfaces 12b, 12c is reduced. Is higher than the dummy molding surface 17 of the second molds 11b and 11c, the curing in the region of the ultraviolet curing resin 19 facing the molding surfaces 12b and 12c of the second mother dies 11b and 11c As a result of proceeding faster than the region of the cured resin 19, the molding surfaces 12a to
12c, in particular, the shape and dimensions of the molding surface 12a are transferred with extremely high precision.

In this embodiment, the UV-curable resin 19 is used as the photo-reactive curable resin. However, other than this, a thermosetting or room temperature-curable epoxy resin, silicone resin, polyester resin, urethane resin, etc. It is also possible to use a resin which is cured by an energy source such as infrared rays, visible rays, electron beams, X-rays and the like.

Next, as shown in FIG. 7, the tip of the knock pin 22 is made to protrude largely from the upper end face of the matrix unit 14 so that the molding surfaces 12a to 12c and the dummy molding surface 1 are formed.
From 7, the ultraviolet curable resin 19 is released together with the release plate 20 to obtain a replica master 21. UV curable resin 19
The replica master 21 of this embodiment, which includes the mold release unit 20 and the mold release unit 20, has a molding surface 12a having a particularly narrow recess or a complicated shape of the matrix unit 14 and a transfer surface 2 corresponding to high precision.
2 has been transferred.

Next, after nickel is deposited on the replica master 21 to form a conductive film, electroforming is performed using nickel as shown in FIG. To form Then, after machining is performed so that the electroformed block 23 has the same shape as that obtained by combining the mother dies 11a to 11c shown in FIG. 1, the replica master 21 is removed from the electroformed block 23.
A mold 24 as shown in FIG. 9 corresponding to a combination of the mother dies 11a to 11c as shown in FIG.

The molding surface 25 of the mold 24 according to the present embodiment manufactured by such a procedure is particularly suitable for the first master mold 11.
It was confirmed that the transfer was performed with extremely high accuracy on the molding surface 12a of FIG.

In this embodiment, the case where electroforming is performed using nickel has been described. However, a single metal such as copper or iron, a composite metal such as nickel-cobalt or nickel-phosphorus, or a combination thereof is used. It is also possible to adopt a laminated structure. Further, instead of shaping the entire mold 24 from the electroformed block 23, when the electroformed block has grown to a certain size in order to reduce the electroforming time, the electroforming is stopped, and the remaining part is removed. The mold 24 may be machined as a separate part and combined with this to form the mold 24.

[0037]

According to the metal mold manufacturing method of the present invention, the master has a first master having a high-precision molding surface and a molding surface having a lower accuracy than the molding surface of the first mother. A dummy mold having at least one second matrix and having a dummy molding surface connected to at least the molding surface of the second matrix, wherein a molding surface of the second matrix and a dummy of the dummy mold are used. The first and second mother dies and the dummy mold are integrally connected so that the molding surface is continuous, and the molding surface and the dummy molding surface are covered with a photoreactive curable resin. Irradiates the first portion of the photo-reactive curable resin facing the molding surface of the first mother die, and then cures the photo-reactive resin facing the molding surface of the second mother die and the dummy molding surface of the dummy mold. After curing the cured resin part, the cured photoreactive cured resin is die cut as a replica master Because it was Unishi, it is possible to easily manufacture the molds precise geometry with thin portion of the mold surface or in mm of complex shape. Further, a large number of highly accurate and inexpensive replica masters and dies can be manufactured from one master without damaging the molding surface of the master.

Before curing the photoreactive curable resin, the first
When defoaming from the photo-reactive cured resin coated on the molding surface of the second mother die and the dummy molding surface of the dummy mold, particularly when this is performed in a vacuum atmosphere, the photo-reaction Thus, a replica master having good transferability can be manufactured.

A release plate is integrally joined to the photoreactive curable resin, and when the photoreactive curable resin is die-cut, a knock pin is abutted against the release plate to form the first and second mother dies. In a case where the photoreactive curable resin is separated from the dummy mold, the photoreactive curable resin can be surely released from the first and second master molds and the dummy mold.

Aluminum is vacuum-deposited on the molding surface of the first matrix, and the surface roughness of the molding surface of the first
The light reflectance of the molding surface of the first master mold and the dummy surface of the second molding die are made smaller than the surface roughness values of the molding surface of the master molding and the dummy molding surface of the dummy mold. If the light reflectance of the dummy molding surface is set higher than
Curing the portion of the photoreactive curable resin facing the molding surface of the mother die first, and then curing the portion of the photoreactive curable resin facing the molding surface of the second mother die and the dummy molding surface of the dummy mold. This makes it possible to manufacture a replica master having good transferability particularly to the surface on which the first matrix is formed.

When the light reflectance of the molding surface of the second mold is set to be higher than the light reflectance of the dummy molding surface of the dummy mold, for example, the surface roughness of the molding surface of the second mold is changed to the value of the dummy. If it is smaller than the surface roughness value of the dummy molding surface of the mold,
Further, it is possible to manufacture a replica master having good transferability to the surface on which the second matrix is formed.

When the photoreactive curable resin is subjected to electroforming to form a mold material, which is machined as a mold and the photoreactive curable resin is removed, a complicated shape is obtained. It is possible to easily manufacture a mold having a highly accurate dimension and shape having a molding surface and a thin portion in mm units.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an exploded state of a matrix in an embodiment of a mold manufacturing method according to the present invention.

FIG. 2 is a sectional view of a matrix unit in which the matrix and the dummy mold shown in FIG. 1 are integrated.

FIG. 3 is a cross-sectional view illustrating a procedure for manufacturing a mold using the matrix unit illustrated in FIG. 2 together with FIGS. 4 to 8, showing a state where a reactive curable resin is applied.

FIG. 4 is a cross-sectional view showing a manufacturing procedure of a mold using the matrix unit shown in FIG. 2 together with FIGS. 3, 5 to 8, in which a release plate is integrally joined to a reactive cured resin. Indicates the status.

FIG. 5 is a cross-sectional view illustrating a procedure of manufacturing a mold using the matrix unit illustrated in FIG. 2 together with FIGS. 3, 4, and 6 to 8, in which a reactive cured resin serving as a replica master is released. This shows a state in which the mold is cut out together with the plate.

FIG. 6 is a cross-sectional view illustrating a procedure of manufacturing a mold using the master mold unit illustrated in FIG. 2 together with FIGS. 3 to 5, 7, and 8, and illustrates a cross-sectional shape of a replica master.

FIG. 7 is a cross-sectional view showing a procedure for manufacturing a mold using the matrix unit shown in FIG. 2 together with FIGS. 3 to 6 and FIG. 8, showing a state in which electroforming has been performed on a replica master. .

8 is a cross-sectional view illustrating a manufacturing procedure of a mold using the matrix unit illustrated in FIG. 2 together with FIGS. 3 to 7, and illustrates a cross-sectional shape of the finally processed mold.

FIG. 9 is a cross-sectional view illustrating a schematic structure of a main part of a conventional mold for injection-molding an ink-jet printhead that is an object of the present invention.

FIG. 10 is a perspective view showing the appearance of a molding piece for forming a fluid path shown in FIG. 9 in a broken state.

FIG. 11 is a perspective view illustrating an appearance of a molding piece for forming a common liquid chamber illustrated in FIG.

DESCRIPTION OF SYMBOLS 11a First mother dies 11b, 11c Second mother dies 12a to 12c Molding surface 13 Metal reflective film 14 Master mold unit 15 Dummy die 16 Connecting plate 17 Dummy molding surface 18 Dowel pin 19 UV curable resin 20 Separation Template 21 Replica master 22 Transfer surface 23 Electroformed block 24 Mold 25 Molding surface

Claims (13)

[Claims] 1. A method of manufacturing a mold having a molding surface having the same shape as the master using a replica master having a transfer surface having a shape corresponding to the molding surface of the master, wherein Providing a first matrix having a molding surface with accuracy and at least one second matrix having a molding surface with lower accuracy than the molding surface of the first matrix; Preparing a dummy mold having a dummy molding surface to be connected to the molding surface of the mother die; and so that the molding surfaces of the first and second mother dies and the dummy molding surface of the dummy mold are continuous. Connecting the first and second mother dies and the dummy mold integrally; forming the integrated molding surfaces of the first and second mother dies and the dummy molding surface of the dummy mold; Coating with a photoreactive curing resin; and the photoreactive curing Irradiating the resin with light to cure a portion of the photoreactive curable resin facing the molding surface of the first matrix; and a method of curing the photoreactive curable resin facing the molding surface of the first matrix. Curing the portion of the photoreactive curable resin facing the formation surface of the second matrix and the dummy molding surface of the dummy mold; and curing the first and second molds and the dummy mold. And die-cutting the photoreactive curable resin cured from above as a replica master. 2. Before the step of curing the photoreactive curable resin, the photoreactive curable resin coated on the molding surfaces of the first and second mother dies and the dummy molding surface of the dummy mold is removed. The method of claim 1, further comprising a step of defoaming. 3. The method according to claim 2, wherein the step of defoaming the photoreactive curable resin is performed in a vacuum atmosphere. 4. The method according to claim 1, further comprising the step of integrally joining a release plate to the photoreactive cured resin,
Removing the photoreactive curable resin from the master mold and the dummy mold includes a step of abutting a knock pin against the release plate to separate the knock-pin from the first and second master molds and the dummy mold. Claim 1.
The mold manufacturing method according to any one of claims 1 to 3. 5. The light reflectance of the molding surface of the first matrix is set higher than the light reflectance of the molding surface of the second matrix and the dummy molding surface of the dummy mold. The mold manufacturing method according to any one of claims 1 to 4, wherein 6. The method according to claim 5, wherein aluminum is vacuum-deposited on a molding surface of the first mother die. 7. The mold according to claim 5, wherein the light reflectance of the molding surface of the second matrix is set higher than the light reflectance of the dummy molding surface of the dummy mold. Production method. 8. The surface roughness of the molding surface of the first matrix is smaller than the surface roughness of the molding surface of the second matrix and the dummy molding surface of the dummy mold. The mold manufacturing method according to claim 5, wherein 9. The mold according to claim 8, wherein the value of the surface roughness of the molding surface of the second mother die is smaller than the value of the surface roughness of the dummy molding surface of the dummy mold. Production method. 10. The photoreactive curable resin is a radical polymerization type ultraviolet curable resin.
The mold manufacturing method according to any one of claims 1 to 9. 11. A step of performing electroforming on the photoreactive cured resin that has been die-cut, a step of machining the electroformed mold material as a mold, and a step of performing machining from the machined mold. The method according to claim 1, further comprising a step of removing the photoreactive resin. 12. A replica master manufactured by the mold manufacturing method according to claim 1. 13. A mold manufactured by the mold manufacturing method according to claim 11.