JP2015020326A - Metal pattern for producing cone-shaped projection molding die, method for producing the same, and method for producing cone-shaped projection molding die - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a metal pattern for producing a cone-shaped projection molding die in which very fine cone-shaped projections with a height of 50 to 500 μm are formed at high accuracy.SOLUTION: A first split mold 61 and a second split mold 62 are mated to form a plurality of cone-shaped recessed parts 64 on a parting line PL. In a state where the first split mold 61 and the second split mold 62 are mated, plating is applied to a plurality of the cone-shaped recessed parts 64 to form a plurality of the cone-shaped recessed projections 11 made of plating metal, and further, plating is applied to a plurality of the cone-shaped projections 11 made of plating metal to form a plating layer 12 on the surface 63 of the first split mold 61 and the second split mold 62. The extremely fine cone-shaped projection 11 with a height of 50 to 500 μm and the plating layer 12 are peeled from the first split mold 61 and the second split mold 62.

Description

  The present invention relates to a mold for manufacturing a cone-shaped projection mold for manufacturing a resin-shaped cone-shaped projection mold for molding a cone-shaped projection, a method for manufacturing the mold, and a method for manufacturing the cone-shaped projection mold. The present invention relates to a method for manufacturing a cone-shaped projection mold using a mold.

Conventionally, a method for manufacturing a fine mold using a plating layer is known. For example, Patent Document 1 (Japanese Patent Application Laid-Open No. 2009-56659) discloses a technique for forming a micro mold having irregularities corresponding to a flow path pattern by electrolytic plating in order to form a flow path pattern of a microfluidic chip. Has been.
The fine mold of Patent Document 1 is formed using an elastomer material layer in which a groove having a rectangular cross-sectional shape is formed. By forming a thin electrode film on such an elastomer material layer and subjecting the electrode film to metal electroplating, a fine mold having a convex stripe pattern having a rectangular cross section is obtained.

JP 2009-56659 A

  The manufacturing method of the fine mold disclosed in Patent Document 1 described above is a suitable method when the shape formed by electrolytic plating is a simple shape such as a convex shape having a rectangular cross section. It cannot be said that this is an appropriate method for obtaining a fine mold having a body-like projection. Since the tip of the cone-shaped protrusion is pointed, in the fine mold manufacturing method described in Patent Document 1, the concave portion of the elastomer material layer is accurately processed into a shape for creating the cone-shaped protrusion. Because it is difficult. Moreover, the shape of the deepest part of the recessed part corresponding to the front-end | tip of a cone-shaped protrusion changes with the electrode film for electrolytic plating, and there also exists a problem that it is difficult to obtain the shape of the recessed part for producing a cone-shaped protrusion. Therefore, even if the elastomer material layer is changed to a metal material layer that is relatively easy to process, the cone-shaped projections have a very fine shape with a height of 50 μm or more and 500 μm or less. The processing of the deepest part of the recess to be cut is still difficult.

  An object of the present invention is to provide a die for manufacturing a cone-shaped projection forming die in which very fine cone-shaped projections having a height of 50 μm or more and 500 μm or less are accurately formed. An object of the present invention is to provide a cone-shaped projection mold that can mold a projection.

Hereinafter, a plurality of modes will be described as means for solving the problems. These aspects can be arbitrarily combined as necessary.
A die for producing a cone-shaped projection mold according to an aspect of the present invention includes a plurality of plated metal cone-shaped projections having a height of 50 μm or more and 500 μm or less, and a plurality of plated metal cone-shaped projections. And a metal layer to which the plating layer is fixed.
According to the cone-shaped projection forming mold manufacturing die configured in this manner, the shape of the tip portion of the fine cone-shaped projection having a height of 50 μm or more and 500 μm or less formed with high precision by metal plating is conical. It is possible to easily manufacture a conical-projection mold that can be copied into a body-shaped hole and the like and can form fine conical-projections having a height of 50 μm or more and 500 μm or less. Further, by forming the plurality of cone-shaped projections and the plating layer integrally, a strong cone-shaped projection molding die can be obtained.

  In this conical-projection-molding mold manufacturing die, the conical-projections made of plated metal may be configured to have a noble metal layer made of a noble metal on the surface. By being configured in this way, when forming the cone-shaped hole of the resin-made cone-shaped projection molding die, it is possible to prevent metal ions from adhering to the cone-shaped hole from the cone-shaped protrusion by the noble metal layer. Hygienic cone-shaped projections can be formed with less precious metal.

  In this conical-projection-molding mold manufacturing die, the conical-projections made of plated metal may be configured to further have conical protrusions made of nickel plating or nickel alloy plating under the noble metal layer. Good. By comprising in this way, the hardness of a cone-shaped protrusion can be ensured by nickel plating or nickel alloy plating, and the highly durable cone-shaped protrusion shaping die manufacturing die can be obtained.

  The manufacturing method of the cone-shaped projection mold according to one aspect of the present invention is to mold a resin-shaped cone-shaped projection mold using the above-mentioned cone-shaped projection mold manufacturing die.

  According to an aspect of the present invention, there is provided a method for manufacturing a conical-projection mold manufacturing die, wherein the first split mold and the second split mold are parted by combining the first split mold and the second split mold. In a state where the cone-shaped recess forming step for forming a plurality of cone-shaped recesses on the line and the first and second split molds are combined, the plurality of cone-shaped recesses are plated to form a plurality of plated metals. In a state where the first plating step for forming the cone-shaped projection made of metal and the first split mold and the second split mold are combined, plating is further applied to the plurality of plated metal cone-shaped projections to obtain the first A second plating step for forming plating layers on the surfaces of the split mold and the second split mold; and a peeling process for peeling a plurality of plated metal cone projections and plating layers from the first split mold and the second split mold; , Including.

  According to the manufacturing method of the conical-projection-molding mold manufacturing die configured as described above, the pyramid-shaped projections made of plated metal are produced from the split surface of the first split mold and the split surface of the second split mold. Therefore, the conical recess can be easily processed, and the conical recess can be formed with high accuracy. In the first plating step, the cone-shaped concave portions formed with high accuracy in this way are filled with the plating metal, so that the cone-shaped projections made of plated metal with high accuracy can be formed. Then, in the peeling step, the plurality of plated metal cone-shaped projections and the plating layer are peeled from the first and second molds, so that the cone-shaped projections of the mold for producing the cone-shaped projection mold are formed. Can be easily obtained.

  In this method of manufacturing a die for forming a cone-shaped projection mold, in the cone-shaped recess forming step, a first split mold having a shape in which the deepest part of the plurality of cone-shaped recesses is divided into two by a parting line and the first mold It may be configured to use a 20% type. By being configured in this way, when the first split mold and the second split mold are divided by the parting line, the deepest part of the cone-shaped recess can be split into two, so that cleaning and plated metal cones The body protrusion can be easily taken out.

  In this method for manufacturing a conical-projection mold, the first split mold and the second split mold are made of at least one of metal and ceramic, and the first plating step includes a plurality of conical shapes. A step of forming a noble metal layer made of a noble metal on the surface of the recess, and a step of forming a plurality of plated metal cone-shaped protrusions by plating nickel or a nickel alloy on the noble metal layer. May be. By being configured in this way, at least one of metal and ceramic is used for the first and second split molds, and the cone projections of the plated metal cone projections are made of nickel or a nickel alloy. When formed, it becomes easy to separate with the noble metal layer on the surface of the cone-shaped projections between them, and the plated-metal cone-shaped projections are fixed to the first and second molds and damaged. Can be prevented by the noble metal layer.

  In this method of manufacturing a conical-projection-molding mold, in the conical recess-forming step, a plurality of sets of the first split mold and the second split mold are combined by combining the plurality of sets of the first split mold and the second split mold. A plurality of conical recesses arranged in a plurality of rows on a plurality of parting lines on the surface of the 20% mold are formed, and in the first plating step, a plurality of sets of the first mold and the second mold are combined. In this state, a plurality of cone-shaped concave portions arranged in a plurality of rows are plated to form a plurality of plated metal cone-like projections arranged in a plurality of rows. In a state where the first and second split molds are combined, a plurality of sets of the first split molds and the second split molds are plated by further plating on a plurality of plated metal cone-shaped protrusions arranged in a plurality of rows. A plating layer is formed on the surface of the 20% mold, and in the peeling process, a plurality of sets of the first and second molds are arranged in a plurality of rows. Peeled once more plating metal of cone-shaped projection and the plated layer are, may be configured to. In this way, by combining a plurality of sets of the first split mold and the second split mold, by forming one plating layer for the plurality of plated metal cone-shaped protrusions arranged in a plurality of rows, Man-hours for plating and peeling can be saved, and the manufacturing cost of the mold for manufacturing the cone-shaped projection mold can be reduced.

  According to the method for manufacturing a conical-projection mold manufacturing die of the present invention, a very fine conical-projection mold having a height of 50 μm or more and 500 μm or less is accurately formed. According to such a cone-shaped projection forming mold manufacturing method and a method for manufacturing a cone-shaped projection molding die, a very fine cone-shaped projection having a height of 50 μm or more and 500 μm or less is formed. It is possible to easily manufacture a resin-made cone-shaped projection mold.

(A) Cross-sectional view schematically showing a preheating step at the film mounting portion of one manufacturing method of the cone-shaped projection forming die, (b) Cross-sectional view schematically showing a state before the mold clamping step at the forming portion . Sectional drawing which shows typically the mold opening process in a formation part following the manufacturing process shown by FIG. Typical sectional drawing for demonstrating the other manufacturing method of a cone-shaped projection shaping | molding die. (A) The expansion perspective view for demonstrating an example of the shape of a cone-shaped protrusion, (b) Sectional drawing of the cone-shaped protrusion of Fig.4 (a). (A) Schematic diagram for explaining an example of the size of each part of the cone-shaped projection, (b) Schematic diagram for explaining another example of the size of each part of the cone-shaped projection, (c) Cone The schematic diagram for demonstrating the further another example of the magnitude | size of each part of a body-shaped protrusion. (A) The top view which shows an example of the arrangement | sequence of the cone-shaped protrusion of the die for cone-shaped protrusion shaping | molding die manufacture, (b) The top view which shows the other example of the arrangement | sequence of a cone-shaped protrusion. (A) An enlarged perspective view for explaining another example of the shape of the cone-shaped projection, (b) a sectional view of the cone-shaped projection of FIG. 7 (a), (c) Other shapes of the cone-shaped projection Typical sectional drawing for demonstrating the example of. Sectional drawing for demonstrating an example of the cone-shaped through-hole of resin cone-shaped projection shaping | molding die. The partial expansion perspective view which shows the external shape of a 1st split mold and a 2nd split mold. The partial expansion perspective view for demonstrating the plating process using the 1st split mold and the 2nd split mold. (A) Schematic sectional view for explaining the formation of the noble metal layer, (b) Schematic sectional view for explaining the formation of the cone-shaped projections by plating, (c) Cone-shaped projections and the plating layer FIG. 4 is a schematic cross-sectional view for explaining peeling of the metal, and (d) a schematic cross-sectional view for explaining fixing of the cone-shaped protrusion and the plating layer to the metal block. (A) Typical sectional drawing for demonstrating formation of a noble metal layer, (b) Typical sectional drawing for demonstrating formation of the cone-shaped protrusion by plating.

  Hereinafter, a cone-shaped projection mold manufacturing die and a manufacturing method thereof according to an embodiment of the present invention will be described with reference to the drawings. Before describing the cone-shaped projection mold manufacturing die and the method for manufacturing the same, first, a process of manufacturing the cone-shaped projection mold using the cone-shaped projection mold manufacturing die will be described.

(1) Manufacture of Cone-Shaped Projection Mold A method for manufacturing a resin-shaped cone-projection mold will be described with reference to FIGS. 1 and 2 is formed by a vacuum forming machine including a film attachment portion and a forming portion. FIG. 1A shows a manufacturing process at a film attachment portion of a vacuum forming machine. As shown in FIG. 1A, the base material 1 attached to the film attachment frame 3 is heated by a heater 5 such as a halogen light source heater or a far infrared heater in the film attachment portion. The base material 1 is made of a thermoplastic film such as polypropylene, polyethylene terephthalate, or polyethylene. By this heater 5, the base material 1 is heated to a temperature in the vicinity of the softening point Tg of the thermoplastic film. Note that an arrow Ar <b> 1 shown in FIG. 1A indicates radiant heat radiated from the heater 5 toward the base material 1.
The heated base material 1 is moved to the forming part of the vacuum forming machine shown in FIG. 1B while being clamped to the film mounting frame 3. A first mold 10 and a second mold 20 are attached to the vacuum forming machine. The first mold 10 and the second mold 20 constitute a cone-shaped projection molding die. Although the configurations of the first mold 10 and the second mold 20 will be described later, the first mold 10 is provided with a cone-shaped protrusion 11, and the tip of the cone-shaped protrusion 11 is formed on the surface of the second mold 20. A gold layer 22 is formed for forming the recessed portion 21 to be fitted. The cone-shaped through hole 51 of the resin-made cone-shaped projection forming mold 50 shown in FIG. 2 is formed by the cone-shaped projection 11 of the first mold 10 and the recess 21 of the second mold 20.

Here, the temperature at which the base material 1 is processed by the first mold 10 and the second mold 20 will be briefly described. When the base material 1 has been moved to the vacuum forming machine, the temperature of the first mold 10 and the second mold 20 is lower than the softening point Tg, but is maintained at a temperature higher than the room temperature Tr. By positioning the film mounting frame 3 with respect to the first mold 10 and the second mold 20, the arrangement of the base material 1 with respect to the first mold 10 and the second mold 20 is completed. The first mold 10 and the second mold 20 are heated to a predetermined temperature around the melting point of the thermoplastic film by the heaters 13 and 24.
In FIG. 1, an arrow Ar <b> 2 indicates the movement of the film mounting frame 3. When the film mounting frame 3 is moved between the first mold 10 and the second mold 20, next, the first mold 10 and the second mold 20 are clamped. The distance between the first mold 10 and the second mold 20 during mold clamping is held by a spacer (not shown). At this time, the temperature of the first mold 10 and the second mold 20 is a temperature suitable for press molding of the base material 1. Therefore, the base material 1 which has already reached the temperature near the softening point Tg quickly rises to the mold temperatures of the first mold 10 and the second mold 20 by contacting the first mold 10 and the second mold 20 by clamping. Be warmed. By this clamping, the shape of the cone-shaped projection 11 is transferred to the base material 1, and the resin-made cone-shaped projection mold 50 having the cone-shaped through hole 51 is molded (see FIG. 2).
Next, in a state where the mold is clamped, cold water is passed through the refrigerant flow paths 14 and 25 of the first mold 10 and the second mold 20 to cool the first mold 10 and the second mold 20. When the first mold 10 and the second mold 20 are cooled to a predetermined temperature sufficiently lower than the softening point Tg of the thermoplastic film forming the base material 1, the mold opening is performed as shown in FIG. . Then, the resin cone-shaped projection mold 50 is taken out from the first mold 10 and the second mold 20.

In the manufacturing method of the above-mentioned cone-shaped projection molding die 50, a method of opening the cone-shaped through hole 51 in the base material 1 made of a thermoplastic film is used. As shown in FIG. 3, injection molding is performed. Thus, the conical-projection mold 50 can be molded. The first mold 10A shown in FIG. 3 is provided with a resin leakage prevention frame 16 in order to form a cavity into which the molten resin flows when the mold is clamped. In the first mold 10A of FIG. 3, other configurations such as the cone-shaped projections 11, the heater 13, and the refrigerant flow path 14 other than the resin leakage prevention frame 16 are the same as those of the first mold 10 of FIG. Further, the second mold 20A of FIG. 3 has a recess 21, a gold layer 22, a copper metal block 23, a heater 24, and a heater 24 except that a mold surface 20a is formed so as to fit inside the resin leakage prevention frame 16. Other configurations such as the refrigerant flow path 25 are the same as those of the second mold 20 in FIG.
When the first mold 10A and the second mold 20A in FIG. 3 are clamped, a cavity having the same shape as the cone-shaped projection mold 50 is formed between the first mold 10A and the second mold 20A. After the cavity is filled with the molten resin by the injection plasticizing apparatus of the injection molding machine that injects the molten resin, the resin is solidified in the clamped state, and the cone-shaped projection molding die 50 is molded.

(2) Conical projection forming mold manufacturing die configuration (2-1) First mold configuration First mold 10 shown in FIG. 1 and first mold 10A shown in FIG. A plurality of cone-shaped projections 11 are formed in an array. 4A is an enlarged perspective view of the cone-shaped protrusion 11 shown in FIGS. 1 and 3, and FIG. 4B is a cross-sectional view of the cone-shaped protrusion 11. The cone-shaped protrusion 11 is formed integrally with the plating layer 12 on the plating layer 12. The shape of the cone-shaped protrusion 11 is substantially conical. The conical generatrix Ge of the conical protrusion 11 is curved so as to be convex inward. Therefore, for example, the cone at a position (h / 2) that is half the height h of the cone-shaped projection 11 (the distance from the bottom surface B1 to the vertex Ve) with respect to the diameter D1 of the bottom surface B1 of the cone-shaped projection 11. When the diameter D2 obtained by cutting the protrusion 11 is compared, D1> (D2 × 2).
The height h of the cone-shaped protrusion 11 is set within a range in which formation by plating is easy, that is, a range of 50 μm or more and 500 μm or less. The length of the base cross section of the cone-shaped protrusion 11, that is, the radius R 1 of the bottom surface B 1 of the cone-shaped protrusion 11 is preferably set to any value from 30 μm to 800 μm.

As described above, since the conical surface of the cone-shaped protrusion 11 is curved so as to protrude inward, the cone-shaped protrusion 11 is flat on the plane so as to pass through the center and apex of the bottom surface of the cone-shaped protrusion 11. Is cut, the two generatrixes (ridges) other than the bottom are curved inwardly. Even if the height h of the cone-shaped protrusion and the length D1 of the bottom side are the same, if the way of bending of the ridge line extending from the vertex Ve toward the bottom surface is different, the sharpness of the cone-shaped protrusion 11 is different. For example, in FIG. 5A, FIG. 5B, and FIG. 5C, three preferable cone-shaped projections 11p, 11q, and 11r are shown. The heights h1, h2, and h3 of the cone-shaped projections 11p, 11q, and 11r are in the range of 50 μm or more and 500 μm or less. Here, h1, h2, and h3 are set to 300 μm.
In the cone-shaped protrusion 11p shown in FIG. 5A, the intersection Po1 is where the plane passing through the center and apex of the bottom surface, the bottom surface, and the conical surface intersect. In the ridge line RL1 connecting the intersection Po1 and the vertex Ve1, the deepest portion DP1 is located farthest from the straight line LL1 connecting the intersection Po1 and the vertex Ve1. The height hh1 (distance from the bottom surface) of the deepest portion DP1 is preferably set to 0.35 × h1 to 0.65 × h1. Here, the height hh1 = 138 μm is set. Moreover, it is preferable that the length di1 of the bottom side of the cone-shaped protrusion 11p is set so that the angle An1 of the vertex Ve1 is 50 degrees or less and 15 degrees or more. Here, the angle An1 is set to 45 degrees, and the base length di1 is 249 μm. Under the conditions as described above, the distance Z1 from the straight line LL1 connecting the intersection Po1 and the vertex Ve1 to the deepest portion DP1 is preferably set in the range of 0.005 × h1 to 0.15 × h1, Then, the distance Z1 to the deepest part DP1 is set to 32 μm.

In the cone-shaped protrusion 11q shown in FIG. 5B, the intersection Po2 is where the plane passing through the center of the bottom surface and the vertex Ve2, the bottom surface, and the conical surface intersect. The height hh2 of the deepest portion DP2 of the ridge line RL2 connecting the intersection Po2 and the vertex Ve2 is set to 143 μm. Further, the length di2 of the bottom side of the cone-shaped protrusion 11q is set such that the angle An2 of the vertex Ve2 is 35 degrees, and the length di2 of the bottom side is 189 μm. Under the conditions as described above, the distance Z2 from the straight line LL2 connecting the intersection Po2 and the vertex Ve2 to the deepest portion DP2 is set to 24 μm.
In the cone-shaped protrusion 11r shown in FIG. 5C, the intersection Po3 is where the plane passing through the center of the bottom surface and the vertex Ve3 intersects with the bottom surface and the conical surface. The height hh3 of the deepest portion DP3 of the ridge line RL3 connecting the intersection Po3 and the vertex Ve3 is set to 148 μm. Further, the length di3 of the bottom side of the cone-shaped protrusion 11r is such that the angle An3 of the vertex Ve3 is set to 20 degrees, and the length di3 of the bottom side is 106 μm. Under the conditions as described above, the distance Z3 from the straight line LL3 connecting the intersection Po3 and the vertex Ve3 to the deepest portion DP3 is set to 13 μm.

The arrangement of the conical projections 11 is a lattice arrangement as shown in FIG. 6A, for example. However, the arrangement of the conical protrusions 11 is not limited to the lattice arrangement, and may be another form such as a staggered arrangement as shown in FIG.
For example, in FIG. 6A, the distance SD between the centers of the two cone-shaped projections 11 arranged in the horizontal direction is 500 μm, and the distance LD between the centers of the two cone-shaped projections 11 arranged in the vertical direction is 500 μm. It is. In the lattice arrangement shown in FIG. 6A, the pitch Pt between the nearest cone-shaped projections 11 is 600 μm. The pitch Pt is preferably set to any value from 300 μm to 3500 μm in order to facilitate the formation of the conical-projection mold 50. In the above example, the cross-sectional diameter is set as R1 × 2 <pitch Pt, the adjacent cone-shaped projections 11 are independent from each other, and the root portions of the adjacent cone-shaped projections 11 are separated from each other. The root portions of the adjacent cone-shaped projections 11 may be set such that the cross-sectional diameter R1 × 2 ≧ pitch Pt is connected, and the adjacent cone-shaped projections 11 may be connected.
When the bottom surface B1 has a circular shape like the cone-shaped projection 11 described above, the preferred range of the cross-sectional diameter R1 is as described above. However, FIGS. 7A and 7B. In the case of a cone-shaped projection other than the cone, such as the cone-shaped projection 11A shown in FIG. 2, the preferable range of the size of the root is the center of the bottom surface of the cone and the point on the bottom surface farthest from the center. The distance (D3 / 2) is any value from 30 μm to 800 μm. Furthermore, it is preferable that the cone-shaped protrusion 11 has a high aspect ratio (height / cross-sectional diameter), for example, a cross-sectional diameter: height = 1: 1.5 to 1: 3. 7A and 7B, only the conical protrusions 11 are shown, and the description of the plating layer 12 is omitted. The cone-shaped protrusion 11A shown in FIG. 7A is curved so that the ridgeline (side) EL is convex inward. Although it is the bottom B2 plane of the cone-shaped protrusion 11A, each side is curved inward, and the shape of the bottom B2 is a star shape. On the other hand, the pyramid surface PS is formed of a curved surface and is curved convexly inward. The apex Ve of the cone-shaped projection 11A also preferably has a radius of curvature of 5 μm or less in order to obtain a shape that can be easily pierced.

For example, the shape of the cone-shaped protrusion is not only when the whole is a cone or pyramid, but the tip is pointed like a cone or pyramid, and the body is a cylinder or prism. It may be. Further, the most conical portion such as a cone or a pyramid may be cut into a dome shape by cutting so that the cross-sectional shape is a substantially arc shape so as not to be chipped. Furthermore, a truncated cone shape such as a truncated cone whose top portion is cut flat like the truncated cone projection 11B shown in FIG. 7C is also included in the shape of the truncated cone projection. In addition, the cone-shaped protrusions may be such that the generatrix or pyramid has a generatrix line or ridgeline that is a straight line, and the cone surface may be a flat surface.
The cone-shaped protrusion 11 is formed of a hard metal (hereinafter also referred to as a first metal) having a Vickers hardness of 150 HV or higher. As such a hard metal, although hardness varies somewhat depending on the plating method, nickel or nickel alloy having a Vickers hardness of about 100 HV to 800 HV is preferably used. Examples of the nickel alloy include nickel cobalt and nickel iron. It is preferable that a noble metal layer 11 a having a uniform thickness is formed on the surface of the conical protrusion 11. Examples of the noble metal include gold, silver, platinum, and palladium. When the cone protrusion 11b is formed mainly by nickel plating or nickel alloy plating, the nickel plating or nickel alloy plating is easily peeled off. Therefore, it is preferable to use palladium. In addition, the value of Vickers hardness here is a value at the time of measuring based on the Vickers hardness test-test method of JISZ2244. When this value is obtained, the value in the table described in the JIS standard is used as the test force.

Below the cone-shaped protrusion 11, a plating layer 12 is formed integrally with the cone-shaped protrusion 11 using the same material as the cone-shaped protrusion 11. On the surface of the plating layer 12, a noble metal layer 12 a is formed of the same material as the noble metal layer 11 a of the conical protrusion 11. Further, the base 12 b of the plating layer 12 is formed of the same material as the cone projection 11 b of the cone projection 11. The thickness of the plating layer 12 is, for example, 120 μm.
In the first mold 10, the plating layer 12 is fixed on the metal block 15. A heater 13 and a refrigerant flow path 14 for adjusting the temperature of the first mold 10 are provided in the metal block 15. The heater 13 and the refrigerant flow path 14 are disposed at a predetermined distance L1, L2 from the mold surface 10a (see FIG. 2). The heater 13 is appropriately selected from various heaters such as a planar heater, a ring heater, and a sheathed heater. Switching between heating and non-heating of the heater 13 is performed by turning on and off the current. For example, cold water flows through the coolant channel 14 during cooling.

(2-2) Configuration of the second mold The mold surface 20a of the second mold 20 is a flat surface. The mold surface 20a is formed of a soft metal (hereinafter also referred to as a second metal) having a Vickers hardness of 100 HV or less. As such a soft metal, gold having a Vickers hardness of about 20 to 50 HV, silver having a Vickers hardness of about 20 to 30 HV, copper having a Vickers hardness of about 40 to 70 HV, aluminum having a Vickers hardness of about 20 to 40 HV, or an alloy thereof is preferable. Used. Considering the possibility that metal ions, fine metal pieces or fine metal particles remain or adhere to the surface of the mold, gold having high thermal conductivity is preferred among them because it hardly causes metal allergy. In addition, when an expensive noble metal such as gold or a gold alloy is used, it is preferable to form a second metal layer on a metal block having a Vickers hardness of 100 HV or less. FIG. 1B shows an example in which a mold surface 20 a is formed of a gold layer 22 laminated on a copper metal block 23. The gold layer 22 can be formed by performing gold plating on a copper metal block 23, for example.

As described above, the second metal preferably has a higher thermal conductivity, for example, preferably 200 W / mK (100 ° C.) or higher, and gold has a thermal conductivity of about 310 to 320 W / mK (100 ° C.). Silver has a thermal conductivity of about 420 to 430 W / mK (100 ° C.), copper has a temperature of about 380 to 400 W / mK (100 ° C.), and aluminum has a temperature of about 220 to 240 W / mK (100 ° C.). The thermal conductivity shown here is a value measured according to JISH7801, and the temperature at the time of measurement is shown in parentheses.
Note that the heater 24 and the refrigerant flow path 25 of the second mold 20 are the same as the heater 13 and the refrigerant flow path 14 of the first mold 10, and the description thereof is omitted.
When the first mold 10 and the second mold 20 are clamped, the tip end portion 11v of the cone-shaped protrusion 11 is fitted into the recess 21. The state in which the tip portion 11v of the cone-shaped protrusion 11 is fitted in the recess 21 is a state in which the cone-shaped protrusion 11 made of the hard first metal is stuck into the mold surface 20a made of the soft second metal. In other words. The concave portion 21 is formed by forming the mold surface 20a of the second mold 20 as a smooth flat plane, and then clamping the first mold 10 and the second mold 20 so that the tip portion 11v of the cone-shaped protrusion 11 can be It can be formed by biting into the mold surface 20 a of the mold 2. That is, when the tip end portion 11v of the cone-shaped protrusion 11 bites into the mold surface 20a of the second mold 20, a part of the mold surface 20a is deformed into a mortar shape to form the recess 21. Once the recess 21 is formed, the tip portion 11v fits into the recess 21 in the second and subsequent mold clamping unless the positional relationship between the first mold 10 and the second mold 20 is changed. In order to form a through-hole through which air can be vented, for example, the height of the cone-shaped protrusion 11 is 300 μm, and the depth of the recess 21 is several μm to several tens μm. At this time, the thickness of the base material 1 is (300 μm−several μm) to (300 μm−several tens μm). The thickness of the base material 1 corresponds to the thickness of a spacer (not shown) that determines a gap when the first mold 10 and the second mold 20 are clamped.

Even if the first mold 10 and the second mold 20 are not properly handled and the mold surfaces 10a and 20a of the first mold 10 and the second mold 20 may come into contact with each other, the cone-shaped projections 11 are formed. The first mold 10 and the second mold 20 are formed so that the thickness L4 of the gold layer 22 is larger than the height L3 of the cone-shaped protrusion 11 (L4> L3) so as not to reach the copper metal block 23. It is configured.
For example, when the aspect ratio of the conical protrusion 11 is 2 and the spacer thickness is 20 μm, the diameter of the above-described recess 21 is 10 μm. As described above, the recesses 21 are very small, and considering that they are arranged in an array, high accuracy is required for mounting the first die 10 and the second die 20 on the press machine. Become a thing. Moreover, such a recessed part 21 can also be formed by the process by a machine tool. However, since high accuracy is required for processing the recess 21, the processing cost increases when the recess 21 is processed by a machine tool. As described above, by forming the cone-shaped projections 11 by biting into the mold surface 20a of the second mold 20, it is possible to save such mounting effort and processing cost. In order to form the recess 21, a recess or hole smaller than the recess 21 is formed in advance, and the recess 21 is formed by encroaching the cone-shaped protrusion 11 into the recess to widen the recess or hole. You can also

(3) Configuration of Resin Cone-Shaped Projection Mold FIG. 8 shows a cross-sectional shape of the resin cone-shaped protrusion mold formed by the above-mentioned cone-shaped protrusion mold manufacturing die. . Since the resin-made cone-shaped projection molding die 50 is generally such that the resin shrinks during cooling after molding, the size of the tapered surface of the cone-shaped through hole 51 is the cone of the first mold 10. There is a tendency that the size of the tapered surface of the protrusion 11 is slightly smaller. The radius R2 of the opening 51a on the first mold 10 side of the cone-shaped through hole 51 is substantially the same as the cross-sectional diameter R1 at the base of the cone-shaped protrusion 11, and takes any value from 50 μm to 500 μm. Formed as follows. The diameter D4 of the through hole 51b on the second mold 20 side of the cone-shaped through hole 51 is set to any value from 1 μm to 200 μm. Therefore, the thickness Th1 of the resin cone-shaped projection mold 50 is set to a value smaller than the height h of the cone-shaped projection 11, but is set to any value between 50 μm and 500 μm. Is preferred. As a result, the thermoplastic resin body for molding the resin cone-shaped projection molding die 50 that is sandwiched between the first mold 10 and the second mold 20 and is in contact with both the first mold 10 and the second mold 20 is formed into a cone. The body-shaped protrusion 11 penetrates and the cone-shaped through hole 51 is formed. The relationship between the radius R2 and the through hole diameter D4 of the resin cone-shaped projection mold 50 may be R2 × 2> D4.

(4) Manufacture of a Cone-Shaped Projection Mold Manufacturing Mold Next, a manufacturing method of the first mold 10 will be described with reference to FIGS. Among the manufacture of the first mold 10, the description will focus on the manufacture of the plated metal conical protrusions 11 and the plating layer 12. The conical projections 11 and the plating layer 12 are formed by performing electrolytic plating or electroless plating on the first split mold 61 and the second split mold 62 shown in FIG. For the first split mold 61 and the second split mold 62, at least one of metal and ceramic is used. Usually, the first split mold 61 and the second split mold 62 are made of metal or ceramic. In FIG. 10, the plating layer 12 is formed on the surfaces 63 of the first divided mold 61 and the second divided mold 62 that are combined with each other, and the conical protrusions 11 are formed in the conical concave portions 64 formed on the surface 63. The state of being done is shown.
For the first split mold 61 and the second split mold 62, for example, stainless steel, aluminum alloy, carbon steel for machine structure, and chrome copper are preferably used as the metal. When the first split mold 61 and the second split mold 62 are formed of such a metal, in order to make it easier to release the plated metal from the first split mold 61 and the second split mold 62, a lubricating property such as paraffin is used. A certain substance may be applied to the surface. Alternatively, for the first split mold 61 and the second split mold 62, for example, silicon, alumina, and a discharge carbon material are suitably used as the ceramic. In order to impart conductivity to the first split mold 61 and the second split mold 62 made of ceramic, the surface may be subjected to treatment such as colloidal application of rare metal such as palladium and sputter deposition.
As the material of the first split mold 61 and the second split mold 62, stainless steel is preferable because it has good corrosion resistance and can be used repeatedly among metals and ceramics.
As shown in FIG. 9, in the state where the first split mold 61 and the second split mold 62 are divided, the conical recess 64 is divided into two by the parting line PL. Therefore, the tapered surface 64a of the conical recess 64 is opened toward the dividing surface PLS. That is, when this conical recess 64 is processed by a die processing machine, it can be cut from the split surface PLS side. Since the deepest portion 64b of the conical recess 64 is in the vicinity of the dividing surface PLS, the conical recess 64 can be easily cut.

Next, the formation process of the cone-shaped protrusion 11 and the plating layer 12 by plating will be described with reference to FIG. 11 (a) to 11 (d) are schematic cross-sections for explaining the manufacturing process, and the size and thickness ratio of each part are accurately described. is not. FIG. 11A shows a state in which the noble metal layers 11a and 12a are formed on the surface 63 and the conical recess 64 of the first split mold 61 and the second split mold 62 that are combined with each other. These noble metal layers 11a and 12a are formed by sputtering, vacuum deposition, vapor phase deposition such as CVD, colloid coating, or the like. Before forming the noble metal layers 11a and 12a, as pretreatment, for example, degreasing, washing with water, acid neutralization, peeling treatment, and the like are appropriately performed.
As shown in FIG. 11B, on the noble metal layers 11a and 12a, for example, nickel is plated to a thickness of 300 μm, and the cone projections 11b of the cone projections 11 and the bases of the plating layers 12 are formed. 12b is formed.
Thereafter, as shown in FIG. 11C, the cone-shaped protrusions 11 are peeled off from the first split mold 61 and the second split mold 62 together with the plating layer 12. At this time, the first split mold 61 and the second split mold 62 are separated from the plating layer 12 and the cone-shaped protrusion 11 at the interface between the first split mold 61 and the second split mold 62 and the noble metal layers 11a and 12a. The Here, the conical projections 11 arranged in a line are peeled from a mold 60 in which one first split mold 61 and one second split mold 62 are combined.
As shown in FIG. 11 (d), the stripped plating layer 12 is fixed to the metal block 15 with the conical protrusion 11 facing up, and the first mold 10 is formed. At this time, a plurality of rows of cone-shaped projections 11 peeled off are fixed on the metal block 15 in a plurality of rows, whereby the first mold 10 in which the plurality of rows of cone-shaped projections 11 are arranged is formed.

(5) Features (5-1)
As described above, when the conical-projection mold manufacturing die obtained by the manufacturing method shown in FIGS. 11 (a) to 11 (d) is used, 50 μm formed with high precision by metal plating. The shape of the tip portion 11v of the fine cone-shaped projections 11, 11A, 11B having a height of 500 μm or less is copied to the cone-shaped through hole 51 and the like, and the fine cone shape having a height of 50 μm or more and 500 μm or less. A conical-projection mold 50 that can form protrusions can be easily manufactured. Further, by fixing the plating layer 12 formed integrally with the plurality of cone-shaped projections 11, 11 </ b> A, 11 </ b> B to the metal block 15, a strong first mold 10 (a mold for producing a cone-shaped projection molding die). Example) can be obtained.
(5-2)
When forming the cone-shaped through hole 51 of the resin-shaped cone-shaped projection mold 50 by the noble metal layer 11a on the surface of the plated-metal cone-shaped projections 11, 11A, 11B, the cone-shaped projection 11, It is possible to suppress adhesion of metal ions, metal powder, and the like from 11A and 11B to the cone-shaped through hole 51, and hygienic cone-shaped projections 11, 11A and 11B can be formed with a small amount of noble metal.

(5-3)
The cone-shaped projections 11, 11 A, 11 B made of plated metal ensure the hardness by the cone-shaped projection 11 b made of nickel plating or nickel alloy plating formed under the noble metal layer 11 a, so that the durability of the first mold 10 is ensured. Increases sex.
(5-4)
By combining the first split mold 61 and the second split mold 62 in the process shown in FIG. 9 (an example of a conical recess forming process), the surface 63 of the first split mold 61 and the second split mold 62 is obtained. A plurality of conical recesses 64 can be easily formed on the parting line PL. If the first split mold 61 and the second split mold 62 are used, the conical recess for producing the plated metal conical protrusion 11 from the split surface PLS can be machined, so that the conical recess 64 can be processed. It becomes easy and the cone-shaped recessed part 64 can be formed accurately. Then, in the plating step (example of the first plating step) shown in FIG. 11B, the cone-shaped concave portion 64 thus formed with high accuracy is filled with nickel plating (example of plating metal). The cone-shaped projection 11 made of nickel plating with high accuracy can be formed. Then, in the step shown in FIG. 11C (an example of a peeling step), the plurality of nickel-plated cone-shaped protrusions 11 and the plating layer 12 are peeled from the first split mold 61 and the second split mold 62. By doing so, the cone-shaped projection 11 of the first mold 10 can be easily obtained.

(5-5)
As shown in FIG. 9, the first split mold 61 and the second split mold 62 having a shape that divides the deepest portion 64b of the plurality of conical recesses 64 by the parting line PL are divided by the parting line PL. If it divides | segments, the deepest part 64b of the cone-shaped recessed part 64 can be divided into two. This facilitates cleaning and removal of the plated metal conical protrusions 11, 11A, 11B.
(5-6)
The first split mold 61 and the second split mold 62 are made of metal or ceramic. When the cone-shaped projection 11 is formed of nickel or a nickel alloy, the tip portion 11v of the cone-shaped projection 11 is easily damaged by the adhesion force between the metal or ceramic and nickel. However, as shown in FIG. 11A, when the noble metal layer 11a is formed on the tapered surfaces 64a of the plurality of conical concave portions 64 (example of the surface of the conical concave portion), the first noble metal layer 11a It becomes easy to separate the split mold 61 and the second split mold 62 from the conical protrusion 11b of the conical protrusion 11, and the conical protrusion 11 is fixed and damaged to the first split mold 61 and the second split mold 62. Can be prevented.

(6) Modifications One embodiment of the present invention has been described above, but the present invention is not limited to the above embodiment, and various modifications can be made without departing from the scope of the invention. In particular, a plurality of embodiments and modifications described in this specification can be arbitrarily combined as necessary.
(6-1)
In the above embodiment, the case where the noble metal layer 11a is formed on the surface of the cone-shaped protrusion 11 has been described. However, the noble metal layer 11a is omitted from the cone-shaped protrusion, and the nickel plating or nickel alloy is exposed on the surface. It may be formed as follows.
(6-2)
In the above-described embodiment, the case where the cone-shaped through hole 51 is formed in the resin-shaped cone-shaped projection molding die 50 by the cone-shaped projection 11 has been described, but the resin-shaped cone-shaped projection molding die 50 has. The cone-shaped hole for forming the cone-shaped projection does not have to penetrate.

(6-3)
In the above embodiment, as shown in FIG. 10, one first split mold 61 and one second split mold 62 are combined to form the cone-shaped projections 11 arranged in a line, and are peeled one by one. Explained when to do. However, as shown in FIG. 12 (a), a plurality of sets in which one first split mold 61 and one second split mold 62 are combined are assembled, for example, all the sets are bolts (not shown). ) To form a die 60 </ b> A for obtaining a plated metal cone projection 11. Then, as shown in FIG. 12B, once the mold 60A is plated, a plurality of conical projections 11 formed under a single plating layer 12A are once formed. It can also be peeled off. In this way, when a mold 60A in which a plurality of sets of the first split mold and the second split mold are combined is used, a plurality of plated metal cone-shaped protrusions 11 arranged in a plurality of rows in one plating step and one Two plating layers 12A can be formed. Thus, in order to manufacture the 1st type | mold 10, by using what combined several sets 1st type | mold and 2nd type | mold, the man-hour of plating and peeling can be saved, and 1st type | mold The manufacturing cost of 10 can be reduced.

DESCRIPTION OF SYMBOLS 10,10A 1st type | mold 20,20A 2nd type | mold 11,11A, 11B Conical protrusion 11a Noble metal layer 11b Conical protrusion part 11v Tip part 12 Plating layer 12a Noble metal layer 12b Base part 50 Conical protrusion shaping | molding die 51 Conical body Shaped through hole 61 1st split mold 62 2nd split mold 64 Cone-shaped recess

Claims (8)

A plurality of plated metal cone-shaped protrusions having a height of 50 μm or more and 500 μm or less;
A plating layer formed integrally with the plurality of plated metal cone-shaped projections;
A die for producing a conical-projection mold, comprising a metal block to which the plating layer is fixed. The plated metal cone-shaped protrusion has a noble metal layer made of a noble metal on the surface,
The die for manufacturing a conical-projection mold according to claim 1. The plated metal cone-shaped projection further has a cone-shaped projection made of nickel plating or nickel alloy plating under the noble metal layer,
A die for producing a conical-projection mold according to claim 2.   A cone-shaped projection molding die made of a resin is molded using the die for producing a cone-shaped projection molding die according to any one of claims 1 to 3. Manufacturing method. A cone-shaped recess that forms a plurality of cone-shaped recesses on the parting lines on the surfaces of the first and second split molds by combining at least one pair of the first split mold and the second split mold Forming process;
A first plating step of plating the plurality of cone-shaped recesses to form a plurality of cone-shaped projections made of plated metal in a state where the first split mold and the second split mold are combined;
In a state where the first split mold and the second split mold are combined, the surfaces of the first split mold and the second split mold are further plated on the plurality of plated metal conical projections. A second plating step for forming a plating layer on the substrate;
A peeling step of peeling the plurality of plated metal cone-shaped protrusions and the plating layer from the first split mold and the second split mold;
The manufacturing method of the metal mold | die for cone-shaped projection shaping | molding die provided with. In the cone-shaped recess forming step, the first split mold and the second split mold having a shape that divides the deepest part of the plurality of cone-shaped recesses into two by the parting line are used.
The manufacturing method of the metal mold | die for cone-shaped projection shaping | molding die manufacture of Claim 5. The first split mold and the second split mold are made of at least one of metal and ceramic,
The first plating step includes a step of forming a noble metal layer made of a noble metal on the surfaces of the plurality of conical recesses, and a nickel or nickel alloy is plated on the noble metal layer to form a plurality of the plated metals. Forming a cone-shaped protrusion.
The manufacturing method of the metal mold | die for cone-shaped projection shaping | molding die manufacture of Claim 5 or Claim 6. In the conical recess forming step, a plurality of sets of the first split mold and the second split mold are combined to form a plurality of sets on the plurality of parting lines on the surfaces of the first split mold and the second split mold. Forming a plurality of conical recesses arranged in a plurality of rows,
In the first plating step, in a state where a plurality of sets of the first split mold and the second split mold are combined, the plurality of conical recesses arranged in a plurality of rows are plated and arranged in a plurality of rows. Forming a plurality of plated metal cone-shaped projections,
In the second plating step, a plurality of sets of the first split mold and the second split mold are combined and further plated on the plurality of plated metal cone-shaped protrusions arranged in a plurality of rows. To form a plating layer on the surface of the first split mold and the second split mold of a plurality of sets,
In the peeling step, a plurality of the plated metal cone-shaped protrusions and the plating layer, which are arranged in a plurality of rows from the plurality of sets of the first split mold and the second split mold, are peeled at a time.
The manufacturing method of the metal mold | die for cone-shaped projection shaping | molding die manufacture as described in any one of Claim 5 to 7.

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