JP2003221693A - Process for manufacturing electrocast core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a process for manufacturing an electrocast core which may easily form a core in a short period of time and can inhibit deformation of the core. <P>SOLUTION: A substrate 11 having at least one processed surface 111 possessing multiple convex and concave parts is placed inside an electroforming tank. A predetermined amount of electroforming liquid is fed into the electroforming tank, and electric currents of opposite polarities are applied to the substrate 11 and the electroforming liquid. A first electrocast layer 12 is formed on the processed surface 111 through electroforming, and a mold surface 121 which complements the convex and concave parts is formed on the surface of the first electrocast layer 12 facing the processed surface 111. A first mold steel 13 is bonded to the surface of the first electrocast layer 12 opposite to the substrate 11 to form a bonded body 60 comprising the first mold steel 13, the first electrocast layer 12 and the substrate 11. The substrate 11 is separated from the first electrocast layer 12 to form a core comprising the first electrocast layer 12 and the first mold steel 13. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for manufacturing an electroformed core.

[0002]

2. Description of the Related Art In a conventional method for producing a core, a base material having a plurality of minute structures is directly electroformed on its surface to form an electroformed layer (for example, nickel layer) having a predetermined thickness. Form a child. When forming a mold core for resin injection molding,
Generally, a certain thickness (eg 20 mm) is required.

However, in general, if an electroformed layer of 1 mm is to be formed, it takes 24 hours to form an electroformed layer. Therefore, if it is desired to form an electroformed layer of 20 mm in thickness, 2
A long electroforming time of 0 days is required, a lot of time is required, and the manufacturing cost is increased. On the other hand, when an electroforming is performed on a base material having a plurality of minute structures on the surface, if an error occurs, it is necessary to perform electroforming again, so that the work efficiency decreases.

FIG. 7 is a schematic view of a conventional method for producing a mold. In this method, a mold surface shell layer 72 is formed on a surface of a mold master 71 in advance by electroforming, and then a shot blasting technique is used. Cleaning the mold surface shell layer 72, then spraying a metal wire on the surface of the electroformed layer by an arc spraying method,
After forming the sprayed layer 73 and repairing the sprayed layer 73, the sprayed layer 73 is bonded to the mold plate 74 by vacuum brazing.

However, in the above-mentioned method, if the thin mold shell layer 72 is formed by electroforming and then another processing method is used, the mold can be thickened and the mold forming time can be shortened. However, since the surface of the electroformed mold surface shell layer 72 generally has a microstructure corresponding to the mold, when performing shot blasting on the mold surface shell layer 72,
The mold surface shell layer 72 is subject to high-pressure impact and is easily broken, and the accuracy of the core deteriorates.

[0006]

SUMMARY OF THE INVENTION It is, therefore, an object of the present invention to provide a method for manufacturing an electroformed core which can rapidly increase the thickness of the core and shorten the electroforming time. Another object of the present invention is to provide a method for manufacturing an electroformed core that can prevent deformation of the core during the manufacturing process.

[0007]

According to the method of manufacturing an electroformed core according to claim 1 of the present invention, a base material having at least one processed surface and a plurality of uneven portions on the processed surface is electrically charged. It is placed inside the casting tank. A predetermined amount of electroforming liquid is placed in the electroforming tank, and electric currents having different polarities are supplied to the base material and the electroforming liquid. The first electroformed layer is formed on the processed surface by electroforming, and the first electroformed layer is formed.
Molded surfaces are formed on the surface of the electroformed layer corresponding to the processed surface to complement the irregularities. Further, the first thickened material is bonded to one surface of the first electroformed layer separated from the base material to form a combined body from the first thickened material, the first electroformed layer and the base material. After separating the base material from the first electroformed layer, an electroformed core is formed from at least the first electroformed layer and the first thickened material.

According to the method of manufacturing an electroformed core according to the second aspect of the present invention, first, the surface of the first thickening material is roughened, and the first thickening material is adhered to the first electroformed layer with an adhesive. Claim 3 of the present invention
According to the method for producing an electroformed core described above, one layer of the welding agent is applied to the surfaces of the first thickened material and the first electroformed layer. The welding agent is heated to bond the first thickened material to the first electroformed layer with the welding agent.

According to the method of manufacturing an electroformed core according to claim 4 of the present invention, the first thickened material is brought into contact with the first electroformed layer, and the laser beam is applied to the first thickened material and the first electroformed layer. The first thickened material is bonded to the first electroformed layer by projecting evenly on the peripheral edge of the. According to the method for producing an electroformed core according to claim 5 of the present invention, after the first thickened material is bonded to the first electroformed layer, the first thickened material is provided on one surface separated from the first electroformed layer. The second electroformed layer is formed by electroforming. The base material is separated from the first electroformed layer, and the second electroformed layer, the first thickening material and the first electroformed layer are formed.
A metal layer is formed from the electroformed layer. The second thickening material is bonded to one surface of the metal layer separated from the first electroformed layer to form a core.

According to the method for producing an electroformed core according to the sixth aspect of the present invention, after the first electroformed layer is formed on the surface of the base material, the base material is separated from the first electroformed layer. According to the method for producing an electroformed core according to claim 7 of the present invention, one surface of the combined body which is apart from the first electroformed layer of the first thickened material is bonded to the second thickened material, and the base material is After separating from the first electroformed layer, a core is formed from the second thickened material, the first thickened material and the first electroformed layer.

According to the present invention, since a thinner electroformed layer is formed by electroforming and then the electroformed layer is combined with a thickening material, the thickness of the core can be increased in a short time and the electroforming time can be shortened. it can. In addition, the present invention forms a first electroformed layer on a base material by electroforming, forms a mold surface on the surface adjacent to the base material of the first electroformed layer to complement the base material, and After performing shot blasting on the surface, the lower surface of the thickened material is bonded to the opposite surface of the first electroformed layer opposite to the molded surface, so that the destruction of the molded surface of the first electroformed layer can be avoided. It is possible to prevent the core from being deformed during the manufacturing process.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. (Embodiment 1) FIGS. 1 and 2 show Embodiment 1 of the present invention, which is an example given for explanation, and the claims are not limited to this structure.

The method of manufacturing an electroformed core according to the first embodiment of the present invention has the following processes. (A) Electroforming: The base material 11 is placed inside an electroforming tank (not shown), and the base material 11 is made of a non-conductive material (for example, acrylic or glass), a conductive material (for example, mold steel), or of this technology. Made of any of the materials familiar to the skilled person. Base material 11
Has a processed surface 111, and the processed surface 111 forms a concave-convex structure having a predetermined number or outer shape by a method such as a yellow light process or machining (these are all known processing techniques, and therefore description thereof is omitted). . A predetermined amount of electroforming liquid is put in the electroforming tank. The electroforming liquid is a nickel sulfamate (Nickel Sulfamate, Ni (SO ₃ NH ₂ ) ₂ ) solution. The substrate 11 and the electroforming liquid have different operating current densities (2 ASD to 8 ASD, ASD is A / 10, respectively).
0 cm ² ) is poured. The first electroformed layer 12 is formed by electroforming on the processed surface 111 of the base material 11, and the processed surface 111 of the first electroformed layer 12 is formed.
Mold surface 1 that complements each other with a plurality of uneven structures on the surface opposite to
21 is formed. The thickness of the first electroformed layer 12 is 1 to 2 mm.

(B) Bonding: Shot blasting is performed on the first thickened material using a spray gun (not shown). In this embodiment, the first thickening material is the first die steel 13, and the lower surface 131 of the first die steel 13 is roughened by shot blasting. The hardness of the first mold steel 13 is HRC30-40. The adhesive 16 (for example, silver paste BR57 or tin paste) adheres the lower surface 131 of the first mold steel 13 to one surface of the first electroformed layer 12 apart from the base material 11 to form the first mold steel 13 and the first mold steel 13.
The combined body 60 is formed from the electroformed layer 12 and the base material 11.

(C) Second electroforming: The combined body 60 is placed inside the electroforming tank, the second electroforming is performed, and the second electroformed layer 14 is formed.
Are formed on the surface of the first die steel 13. The thickness of the second electroformed layer 14 is approximately 1 to 2 mm. As shown in FIG.
During the second electroforming, metal ions are attached to the space A between the first mold steel 13 and the first electroformed layer 12.

(D) Separation: The substrate 11 is separated from the first electroformed layer by a mechanical method, and the metal layer 10 is formed from the first electroformed layer 12, the first die steel 13 and the second electroformed layer 14. . Metal layer 1
The thickness of 0 is approximately 8 mm to 10 mm. (E) Second connection: forming a plurality of screw holes in the metal layer 10. The metal layer 10 is fixed to the second thickened material through the screw holes with the plurality of screws 15. The second thickening material is the second mold steel 20,
The hardness of the second mold steel 20 is HRC30-40. Second
The mold steel 20 and the metal layer 10 are combined to form a core having a thickness of about 20 mm.

In the present embodiment, a core having a thickness of 20 mm can be manufactured by electroforming only twice. The electroformed layer 12 and the electroformed layer 14 each having a thickness of 1 to 2 mm are formed, namely, 2 to 4
A mm electroformed layer is prepared. This example significantly shortens the electroforming time and reduces the manufacturing cost as compared with the time required to form an electroformed layer of 20 mm in the electroforming of the prior art.

When the first mold steel 13 is adhered to the first electroformed layer 12, the surface of the first mold steel 13 is avoided in order to prevent the surface of the first electroformed layer 12 from being too smooth and making the adhesion difficult. Then, shot blasting is performed to increase the adhesion area and the frictional force between the surface of the first die steel 13 and the first electroformed layer 12. Therefore, the first die steel 13 is firmly fixed to the first electroformed layer 12
Can stick to.

Further, in this embodiment, since the shot blasting is performed not on the first electroformed layer 12 but on the surface of the first die steel 13, the mold surface 121 of the first electroformed layer 12 is exposed to the high pressure of shot blasting. Not destroyed. Therefore, the deformation and damage of the first electroformed layer 12 and the mold surface 121 of the core can be avoided.

As indicated by A in FIG. 3, while the second electroformed layer 14 is being electroformed, metal ions are applied to the first electroformed layer 12 and the first electroformed layer 12.
It adheres to the space between the mold steel 13 and forms an electroformed layer.
Therefore, the effect of filling the void between the first die steel 13 and the first electroformed layer 12 can be achieved.

As the first thickening material and the second thickening material, other materials familiar to those skilled in the art can be adopted. To summarize the above, in the process of this example, first, an electroformed layer is formed on the surface of the base material by electroforming, and a mold surface that complements the base material is formed on the electroformed layer. Also, after adhering the thickened material to the electroformed layer,
Separate them from the substrate. The thickening material can be fixed to a metal layer composed of two electroformed layers and the thickening material to form a core having a predetermined thickness in a short time. Therefore, in this embodiment, the core manufacturing time can be shortened and the core deformation can be avoided.

(Embodiment 2) The present invention has various other modifications only in the details. As shown in FIGS. 4 and 5, according to the method for manufacturing an electroformed core, which is Embodiment 2 of the present invention, it has the following processes.

(A) Electroforming: The base material 31 is placed inside the electroforming tank described in the first embodiment, and the base material 11 has a processed surface 311 having a concavo-convex structure formed with a predetermined amount and outer shape. Pour a predetermined amount of electroforming liquid into the electroforming tank. It is to be noted that currents having different polarities are respectively passed through the base material 31 and the electroforming liquid to form the first electroformed layer 32 on the processed surface 311 of the base material 31 by electroforming, and the processed surface 311 of the first electroformed layer 32 is formed. Mold surface 321 that complements each other with a plurality of uneven structures on the surface opposite to
To form.

(B) Separation: First electroformed layer 3 by mechanical method
2 is separated from the base material 31. (C) Bonding: After the welding agent 36 is applied to the surfaces of the first thickening material 33 and the first electroformed layer 32, the welding agent 36 is heated and the first thickening material 33 is bonded by the welding agent 36. First electroformed layer 32
Combine with. The first thickened material 33 and the first electroformed layer 3
The temperature and pressure are continuously applied to the second thickening material 3
3 is firmly bonded to the first electroformed layer 32.

(D) Second connection: A plurality of screw holes are formed in the first thickening material 33, and the first thickening material 33 and the first electroformed layer 32 are fixed to the second thickening material 40 with screws 35. Then, the core of this embodiment is formed. In the second embodiment, since the first electroformed layer 32 is bonded to the first thickening material 33 and then they are fixed to the second thickening material 40, the core can be thickened in a shorter time. .

Further, since the first electroformed layer 32 has the mold surface 321 corresponding to the concavo-convex structure of the base material 31, the first electroformed layer 32 can be combined with the first thickening material 33 to form a core. . (Embodiment 3) As shown in FIG. 6, the electrocasting core manufacturing method according to Embodiment 3 of the present invention has the following different points from Embodiment 2.

The first die steel 53 is joined to the first electroformed layer 52 by a laser beam. Laser beam (wavelength is 1064μ
m) is evenly projected onto the peripheral edges (shown at point D) of the first die steel 53 and the first electroformed layer 52. The laser beam diameter is 0.
It is 2 to 0.6 mm. The first die steel 53 and the first electroformed layer 52 occupy a half welding point (0.1 to 0.3 mm). The first thickened material 53 is irradiated with the laser beam to the first electroformed layer 5
Since it is combined with 2, the manufacturing efficiency of the core can be effectively improved,
The same effect as that of the first embodiment can be achieved.

[0028]

The present invention has the following effects. (A) Since a thinner electroformed layer is formed by electroforming and the electroformed layer is bonded to the thickened material, the thickness of the core can be increased in a short time and the electroforming time can be shortened. (B) A first electroformed layer is formed on a base material by electroforming, and a mold surface that complements the base material is formed on the surface of the first electroformed layer adjacent to the base material. After shot blasting the lower surface of the thickened material, the lower surface of the thickened material is bonded to the surface of the first electroformed layer opposite to the mold surface. For this reason, it is possible to avoid the destruction of the mold surface of the first electroformed layer and prevent the deformation of the core during the manufacturing process.

[Brief description of drawings]

FIG. 1 is a diagram showing a flow of a method for manufacturing an electroformed core according to Example 1 of the present invention.

FIG. 2 is a schematic diagram for explaining a method for manufacturing an electroformed core according to Example 1 of the present invention.

3 is a partially enlarged view of FIG.

FIG. 4 is a diagram showing a flow of a method for manufacturing an electroformed core according to Example 2 of the present invention.

FIG. 5 is a schematic view showing a method for manufacturing an electroformed core according to Example 2 of the present invention.

FIG. 6 is a schematic diagram for explaining a method of bonding a die steel to a first electroformed layer by a laser in a method for manufacturing an electroformed core according to Example 3 of the present invention.

FIG. 7 is a schematic diagram for explaining a conventional die manufacturing method.

[Explanation of symbols]

10 metal layers 11 Base material 12 First electroformed layer 13 First mold steel 14 Second electroformed layer 15 screws 16 Adhesive 20 Second mold steel 31 Base material 32 First electroformed layer 33 First thickening material 35 screws 36 Welding agent 40 Second thickening material 52 First electroformed layer 53 1st die steel 60 combination 111 Processing surface 121 Mold surface 311 Processing surface 321 Mold surface

Claims (7)

[Claims] 1. A base material having at least one machined surface and having a plurality of concave and convex portions on the machined surface is disposed inside an electroforming tank, and a predetermined amount of electroforming liquid is introduced into the electroforming tank. Then, the base material and the electroforming liquid are respectively supplied with electric currents having different polarities to form a first electroformed layer on the processed surface by electroforming,
Formed on the surface of the first electroformed layer corresponding to the processed surface is a mold surface that complements the uneven portion, and the first thickening material is used as the first thickened material.
Bonding to one surface of the electroformed layer separated from the base material, a combined body is formed from the first thickening material, the first electroformed layer and the base material, and the base material is the first electroformed layer. After the separation, an electroformed core is formed from at least the first electroformed layer and the first thickened material. 2. The electroformed core according to claim 1, wherein the surface of the first thickened material is roughened, and the first thickened material is adhered to the first electroformed layer with an adhesive. Production method. 3. A layer of welding agent is applied to the surfaces of the first thickening material and the first electroformed layer, the welding agent is heated, and the first thickening material is applied to the first thickening material with the welding agent. The method for producing an electroformed core according to claim 1, wherein the electroformed core is bonded to the electroformed layer. 4. The first thickened material is brought into contact with the first electroformed layer, and a laser beam is projected evenly on the peripheral portions of the first thickened material and the first electroformed layer to form the first thickened material. The method of manufacturing an electroformed core according to claim 1, wherein a thickening material is bonded to the first electroformed layer. 5. The second thickening material is bonded to the first electroformed layer, and a second electroformed layer is formed by electroforming on one surface of the first thickened material separated from the first electroformed layer. Then, the base material is separated from the first electroformed layer, a metal layer is formed from the second electroformed layer, the first thickened material and the first electroformed layer, and the second thickened material is formed as described above. The method for producing an electroformed core according to claim 1, wherein the electroformed core is formed by bonding the metal layer to one surface of the metal layer which is separated from the first electroformed layer. 6. The electroformed core according to claim 1, wherein the base material is separated from the first electroformed layer after the first electroformed layer is formed on the surface of the base material. Production method. 7. A surface of the bonded body, which is away from the first electroformed layer of the first thickened material, is bonded to a second thickened material, and the base material is separated from the first electroformed layer. The method for producing an electroformed core according to claim 1, wherein the electroformed core is formed from the second thickened material, the first thickened material, and the first electroformed layer.