1245813 九、發明說明： 【發明所屬之技術領域】 電鑄 +本發明係關於一種電鑄翻模技術，特別是指一種強化 权仁炼射增厚層結合強度之方法。 【先如技術】 傳統的模具加工業通常使用CNC工具機、靠模仿雕機或放 工方式，直接在模具鋼上進行切削。惟受到工具及工且 精^的限制，對於微細的幾何外形、特殊的光學性質及精^要 f高的模具’如製作微元件所_微模具，傳統的機械加二便 然法勝任，須利用電鑄的方式製模。1245813 IX. Description of the invention: [Technical field to which the invention belongs] Electroforming + The present invention relates to an electroforming turning mold technology, and particularly to a method for strengthening the bonding strength of the Quanren refining and thickening layer. [Such as technology] The traditional mold processing industry usually uses CNC machine tools, imitating engraving machines or machining methods to directly cut on the mold steel. However, due to the limitations of tools and workmanship, for the molds with fine geometric shapes, special optical properties, and high precision, such as the micro-mold institute _ micro-molds, traditional mechanical plus two methods will suffice. Molding by electroforming.
電鑄模具是利用電鍍的方式，於母模(mandrel)上產生一 層厚的金屬殼模，而後從母模上剝離形成母模的複製品，再經 由機械加工修整製成模具，舉凡各種精密度及複雜性高或傳= ，械加工困難且消耗大量人力的模具，皆可採用電鑄翻模技術 豉作及大量生產。由於其複製品精度可達2· 5//m，表面解析 度可達0.02〜0· 05//in，因此適用於CD、車燈反光片模具、液 晶顯示器用導光板模具的製作。 、v' 不過，由於電鑄沉積的速度甚慢，約僅〇· 5-1 mm/day，以 厚度30=111的電鑄模仁為例，入槽電鑄時間須耗費8週的時 間，電鑄沉積速度慢是電鑄製模極待克服的技術瓶頸。 金^射是-輸理性金屬沉積技術，她金聽射的沉 積速率高（約20-180 kg/hrs)，可應用於電鑄模仁的模後支撐 與增厚，大幅縮短模仁入槽電鑄的時間，達到快速製模的目的。 然而’熔射增厚層與電鑄層之間為機械鍵結，由於溶射增 厚層係由數百遏金屬薄膜堆疊喊，目前商業化的熔射設備所 得到的熔射皮财為張應力，因此隨著騎層厚度增加，當溶 射增厚層的張應力大於熔射層與底材的鍵結力時，熔射增厚層 便有脫層之虞’熔射層的結合強度不佳是熔射增厚法最主要的 缺點。其次熔射作業中因熱導致的電鑄層變形、溶射層本體強 5 1245813 判題’都是熔射增厚技躺改善的缺點。 ;=1:結合強度，並麟包覆 以下㈡成ΐ?\2 ’本發明強化增厚模仁結構之方法包括 鑄液中進行電鑄包覆；繼而，熔射增厚層 補強肋上，如有必要，預參、斤1+雄如二电~双权及其立體 粗化；接著，將熔射辦严声嬙口、，曰並施以金剛砂喷砂 ^ 覆，取後，分離原型母模與電鑄金屬模仁。 為使鈞局貝審查委員及熟悉本項技藝之人士，处、、主、 解本發明之技術手段、特微金:此’月邊瞭 式詳細說明如後 _舉實施例配合圖 【實施方式】 來見戦仁熔射增厚層結合強度的流程圖請 首先，提供原型母模（步驟110)二d圖:;v 2驟12〇)，將此原型母模浸人—第」電鑄液進J Jd ，-厚1-3 —電鑄殼層10，如第2A圖所示U匕 鑄液之成分係包含鎳、銅及其合金， 密度5-25ASD，電鑄液溫度2G_8(rc。~之_作參數為電流 爾後，熔射立體補強肋（步驟13〇);如 層，可以溶射方式时複Hi Ϊΐ: 1其中進行熔射以形成立體補強肋2〇之材料， 可為銅、鐵、鎳、鈦、不鏽鋼及其合金等。溶射操作參數如^ 1245813 熔射，離：40〜60 cm ; (ii)熔射壓力·· 35—7〇 psi ; (ni)壓縮 空氣堡力.：7G psi ; (iv遠縮空氣流量·· 52 OT; (v)乙诀魔 力· 15 psi，（vi)乙炔流量：40 CFM ; (vii)氧氣壓力·· 3〇 pSi ; (viii)氧氣流量·· 44 CFM。 、、其次，進行第一次電鑄包覆（步驟14〇);即將具有立體 補強肋之賴殼模浸人第二電鑄射，第二賴液之成分與操 作條件，可與第一電鑄液相同或另做調整。置入第二電鑄液中 =8〜12小時後，立體補強肋2〇、經電鑄包覆後可與原電禱殼模 進一步固結為一體，即形成具立體補強肋之電鑄殼模3〇(第 2C 圖）。 、、接著，為增強熔射增厚層與電鑄殼模的結合效果，把具立 體補強肋^電鑄殼模30預先施以金剛砂喷砂、粗化（步驟ι51， 、=圖未示），喷砂壓力_ 5㈣psi，再進行熔射錄銘合 步驟152)，炫射-鎳!呂合金層5G於具立體補強肋之電 30上’如第2C圖所示，鎳銘合金可與具立體補強肋之 電麵，模3〇中所含之錄共同形成一鍵結層。 认雜巧’再熔射增厚層（步驟15G)，溶射—金屬增厚層70 金層50上，增厚層70之材料選擇可與立體補強肋相 欽、不鐵鋼及其合金等；熔射後之增厚層 70=面機械加工·(步驟161)後，進行第二次輯包覆 i-rU ’即可形成完整的電鑄模仁90，然後分離原型母 核/、電麵模仁（步驟17〇)即可。 將二=電鑄包覆的賴模何無纽螺職合或 接合，便為一完整的模具。 ίΐ明的是，本發明所採用之熔射技術可為火焰粉 線材熔射或電弧熔射等。再者，立體補強肋-般 :士二強力量，使電鑄殼模與增厚層間可以緊密固 ίίίϊ銘合金層及金剛砂之噴砂粗化並非絕對必要； 另卜’祕金屬增厚層的表面機械加工研磨步驟，可提昇二次Electroforming molds are produced by electroplating. A thick metal shell mold is produced on the master mold, which is then peeled off from the master mold to form a replica of the master mold. The mold is then machined and trimmed to make the mold. And molds with high complexity or transmission =, mechanical processing is difficult and consumes a lot of manpower, all can use electroforming turning mold technology to operate and mass production. The accuracy of its replica can reach 2 · 5 // m, and the surface resolution can reach 0.02 ~ 0 · 05 // in, so it is suitable for the production of CD, lamp reflector film molds, and light guide plate molds for liquid crystal displays. , V 'However, because the speed of electroforming deposition is very slow, only about 0.5-1 mm / day, taking the thickness of the electroforming mold core as an example, the electroforming time into the tank takes 8 weeks. The slow casting deposition speed is a technical bottleneck to be overcome by electroforming molds. Gold injection is a metal deposition technology with high deposition rate (about 20-180 kg / hrs). It can be used for post-mold support and thickening of electroformed mold cores, which greatly shortens the power of mold cores. Casting time to achieve the purpose of rapid molding. However, there is a mechanical bond between the thermal spray thickened layer and the electroformed layer. Because the thermal spray thickened layer is stacked by hundreds of metal thin films, the thermal spray coatings obtained by current commercial thermal spray equipment are tensile stresses. Therefore, as the thickness of the riding layer increases, when the tensile stress of the dissolution-thickening layer is greater than the bonding force between the spray-shot layer and the substrate, the spray-thickness layer may be delaminated. It is the main disadvantage of the shot thickening method. Secondly, the deformation of the electroformed layer due to heat and the strong body of the dissolution layer in the thermal spraying operation. ; = 1: Combined strength, and the following coatings are coated by the combination? \ 2 'The method for strengthening the thickened mold core structure of the present invention includes electroforming coating in a casting solution; then, the shot-thickening layer reinforces the ribs, If necessary, pre-reference, Jin 1+ Xiongru Erdian ~ Shuangquan and its three-dimensional roughening; then, slam the shotgun tightly, and apply blasting with emery blasting ^, after taking, separate the prototype Master mold and electroformed metal mold. In order to enable Jun Jubei's review members and those familiar with this technology, the technical means, special fines, to explain, explain, explain, and explain the present invention are detailed below. ] To see the flow chart of the cohesive strength of the Coix injection thermal spray thickened layer, first, provide a prototype master mold (step 110), two d pictures:; v 2 step 12〇), immerse this prototype master mold-the first "electroforming" Liquid injection J Jd, -thickness 1-3-electroformed shell layer 10, as shown in Figure 2A, the composition of the U-die casting solution includes nickel, copper and its alloy, density 5-25ASD, electroforming solution temperature 2G_8 (rc . ~ __ The parameter is the current, and then the three-dimensional reinforcing ribs are sprayed (step 13); if the layer is, it can be recovered when the spray method is used. Hi Ϊΐ: 1 where the material is sprayed to form the three-dimensional reinforcing ribs 20, which can be copper. , Iron, nickel, titanium, stainless steel and its alloys, etc. Dissolution operation parameters such as ^ 1245813 shot, away: 40 ~ 60 cm; (ii) shot pressure · 35-7 psi; (ni) compressed air force .: 7G psi; (iv telecontracting air flow · 52 OT; (v) ethic magic · 15 psi, (vi) acetylene flow: 40 CFM; (vii) oxygen pressure · 30pSi; (viii) Oxygen flow 44 CFM. Second, the first electroformed coating (step 14); the shell mold with three-dimensional reinforcing ribs is immersed in the second electroformed shot, the composition and operation of the second shell liquid The conditions can be the same as those of the first electroforming solution or adjusted separately. After being placed in the second electroforming solution = 8 to 12 hours, the three-dimensional reinforcing ribs 20 can be further fixed with the original electric prayer shell mold after being covered by electroforming. As a whole, the electroformed shell mold 30 with three-dimensional reinforcing ribs is formed (Fig. 2C). Then, in order to enhance the combined effect of the thickening layer and the electroformed shell mold, the three-dimensional reinforcing ribs are electrically charged. The casting mold 30 was previously blasted and roughened with silicon carbide (step 551,, == not shown), and the blasting pressure was _ 5㈣psi, and then the injection shot inscription step 152 was performed, and the dazzling-nickel! Lu alloy layer 5G On the electric 30 with three-dimensional reinforcing ribs, as shown in FIG. 2C, the nickel alloy can form a bonding layer with the electric surface with three-dimensional reinforcing ribs, and the records contained in the mold 30. Spray-thickening layer (step 15G), dissolution-metal thickening layer 70 On the gold layer 50, the material selection of the thickening layer 70 can be compatible with the three-dimensional reinforcement ribs, Iron steel and its alloys, etc .; thickened layer 70 after surface injection = surface machining · (step 161), a second series of coating i-rU 'can be performed to form a complete electroformed mold 90, and then the prototype is separated The mother core / electrical surface mold kernel (step 17) can be used. The two = the electroformed cladding of the Lai Mo He Wu Niu screw fit or join, it is a complete mold. It is clear that the present invention The spraying technology used can be flame powder wire spraying or arc spraying. In addition, the three-dimensional reinforcement ribs-like: Shi Erqiang strength, so that the electroformed shell mold and thickened layer can be tightly fixed. The sand blasting and roughening is not absolutely necessary; In addition, the surface mechanical grinding step of the thickened layer of the secret metal can improve the secondary
7 1245813 起 電鑄包覆之輯模仁絲品質 模之結合強度鱗絕對必要。野於強化从層與 定本而已，轉用r ，離本創作之技料後，巧 蓋於本創作之申請專利範圍内。：、、艾匕”修飾，皆應涵 【圖式簡單說明】 =圖係本發明方法之主要流程圖；及 A至2E圖係本發明方法各階 【圖式符號說明】 汉、、、口構不思圖。 1〇電每殼模 20立體補強肋 30具立體補強肋之電鑄殼模 50鎳鋁合金層 ' 7〇熔射增厚層 90電鑄模仁 步驟110提供原型母模 步驟120形成電鑄殼模 步驟130熔射立體補強肋 步驟140第一次電鱗包覆 步驟151金剛砂噴砂粗化 步驟152熔射鎳鋁合金層 步驟150熔射增厚層 步驟161表面機械加工研磨 步驟160第二次電鑄包覆 步驟Π0分離原型母模與電鑄模仁7 From 1245813 The quality of the cores of electroformed coatings is absolutely necessary. Rather than strengthening the layers and the final version, they switched to r. After leaving the material of this creation, they were covered by the scope of the patent application for this creation. ： 、、 艾 dagger "modification should all include [Schematic description of the diagram] = The diagram is the main flowchart of the method of the present invention; and the diagrams A to 2E are the various stages of the method of the present invention [Schematic symbol description] I don't think about it. 1．Electricity: 20 solid reinforcement ribs per shell mold. 30 electroformed shell molds with 3D reinforcement ribs. 50 nickel-aluminum alloy layer. Electroformed shell mold step 130, shot three-dimensional reinforcement ribs step 140, first electric scale coating step 151, emery blasting, roughening step 152, shot nickel alloy layer, step 150, shot thickened layer, step 161, surface machining, step 160, The secondary electroforming coating step Π0 separates the prototype master and the electroforming mold