TW201438866A - Rapid tooling manufacturing method - Google Patents

Abstract

This invention relates to a rapid tooling manufacturing method, comprising the following steps: (A) preparing a mold frame having a processing tank; (B) installing a prototype workpiece having a prototype structure in the processing tank and pouring a first plastic body to be cured to form a first reproduction mold having a first reproduction structure; (C) taking out and separating the prototype workpiece and the first reproduction mold, installing the first reproduction mold to the processing tank, and then pouring a second plastic body not bonded to the first reproduction mold to be cured to form a second reproduction mold having a second reproduction structure; (D) taking out and separating the first reproduction mold and the second reproduction mold, installing the second reproduction mold to the processing tank, and then pouring a third plastic body not bonded to the second reproduction mold to be cured to form a rapid tooling having an impression structure; and finally, taking out and separating the rapid tooling and the second reproduction mold.

Description

Rapid mold manufacturing method

The present invention relates to a method for manufacturing a rapid mold, and more particularly to a method for manufacturing a high-precision rapid mold.

Rapid tooling (RT) is a molding technology that is currently used to shorten product development time and save development costs. It can mass produce prototype artifacts produced by rapid prototyping to verify the prototype. Product performance and market response of the workpiece.

Referring to FIG. 1(A) to FIG. 1(I), the production process of the existing rapid mold is shown. Referring to Fig. 1(A), first, a prototype workpiece 91 is mounted in a mold frame 92 for making a mold. The prototype workpiece 91 is a micro-mechanism, and a plurality of minute prototype structures 911 are formed on the surface. For example, the prototype workpiece 91 may be a micro-gear having a diameter of a few millimeters (mm) and having a plurality of micrometer (μm) graded prototype structures 911 formed on its surface.

Referring to FIG. 1(B) and FIG. 1(C), the prototype workpiece 91 is mounted on the mold frame 92 with its prototype structure 911 facing upward, and then a curable plastic material (for example, silicone) is filled in the mold frame. In 92, the plastic material is solidified and molded, thereby forming a first turning mold 93. According to the characteristics of the above processing steps, the first reshaping mold 93 forms a plurality of first revolving structures having a prototype structure 911 complementary to the prototype workpiece 91 after solidification molding. 931.

Referring to FIG. 1(C) to FIG. 1(F), a second reshaping mold 95 is then produced in accordance with the first reshaping mold 93. First, the first turning mold 93 and the prototype workpiece 91 are sequentially taken out from the mold frame 92 and separated from each other, and then the first turning mold 93 is mounted in the upward direction of the first turning structure 931 thereof. In the frame 92. Subsequently, a release layer 94 is applied to the surface of the first recursive structure 931 of the first reshaping mold 93, and then a second reversing mold 95 is formed in a manner similar to the aforementioned molding (silicone) molding. Accordingly, the second revolving structure 951 on the surface of the second reshaping mold 95 is substantially complementary to the first revolving structure 931 of the first reshaping mold 93. Finally, the first turning mold 93 and the second turning mold 95 are removed from the mold frame 92, and then the two are separated, that is, the second turning mold 95 is completed.

Referring to FIG. 1(G) and FIG. 1(H), after the manufacturing step of the second reshaping mold 95 is completed, the second reshaping mold 95 can be installed in the mold frame in the upward direction of the second reversing mold 951. In 92, a plastic metal resin (a resin mixed with a metal powder) is further filled, and the metal resin is solidified and molded, that is, a rapid mold 96 is completed. Similarly, the surface of the rapid mold 96 will form an embossed structure 961 that is complementary to the second revolving structure 951 of the second reshaping mold 95.

Referring to FIG. 1(I), after the manufacturing process of the above-described rapid mold 96 is completed, the hot stamping process can be performed using the rapid mold 96 to produce a replica workpiece 97 having a surface structure complementary to the second reversing structure 951. Ideally, the size and surface structure of the replicated workpiece 97 should be identical to the original prototype workpiece 91. However, in the process of making the second reshaping mold 95, due to the first turn The surface of the mold 93 must be coated with a release layer 94 to prevent the first and second molds 93, 95 of the same material (silicone) from being separated, and the thickness of the release layer 94 is at least several micrometers ( For example, 3 microns or more). Therefore, in the case where the sizes of the first revolving structure 931 and the second reversing structure 951 are both micron grades, the release layer 94 may seriously affect the dimensional accuracy of the second reversing structure 951 and further affect the rapid mold 96. The accuracy of the embossed structure 961, which results in the reproduction of the workpiece 97 by the rapid mold 96, produces a non-negligible manufacturing error in both size and precision.

Accordingly, it is an object of the present invention to provide a manufacturing method which can improve the dimensional accuracy of a rapid mold.

Thus, the present invention proposes a method of manufacturing a rapid mold. The rapid mold is used to make a replica workpiece of a prototype workpiece whose surface forms at least one prototype structure. The manufacturing method of the present invention comprises the steps of: (A) preparing a mold frame having an open processing groove. (B) mounting the prototype workpiece in the machining groove of the mold frame and opening the prototype structure of the prototype workpiece to the outside. Subsequently, a first colloid not attached to the prototype workpiece is poured into the processing groove of the mold frame, and the first colloid is solidified into a first reversing mold, and the surface of the first rectifying mold is formed. At least one first revolving structure complementary to the prototype structure. (C) removing the first reshaping mold from the prototype workpiece from the mold frame and separating the first reversing mold from the prototype workpiece. Then, the first rectifying mold is installed in the processing groove of the mold frame, and the first reversing structure of the first reversing mold is oriented Open outside. Subsequently, a second colloid not attached to the first reshaping mold is poured into the processing groove of the mold frame, and the second colloid is solidified into a second reversing mold, and the second reversing mold is The surface system forms at least one second revolving structure that is complementary to the first revolving structure. (D) removing the first and second molds from the mold frame, and separating the first mold and the second mold. Then, the second turning mold is installed in the processing groove of the mold frame, and the second turning structure of the second turning mold is opened outward. Subsequently, a third colloid not attached to the second reshaping mold is poured into the processing groove of the mold frame, and the third colloid is solidified into a rapid mold, and the surface of the rapid mold forms at least one complementary The embossed structure of the second revolving structure.

In an embodiment, after the step (D), a step (E) is further included: the second mold and the rapid mold are removed from the mold frame, and the second mold is Rapid mold separation.

In one embodiment, one of the first colloid and the second colloid is silicone, and the first colloid and the second colloid are rubber.

Preferably, the first colloid is silicone and the second colloid is rubber.

In one embodiment, the third colloid is a resin comprising a metal powder.

Preferably, the metal powder is aluminum powder and the resin is an epoxy resin.

More preferably, the third colloid further comprises strontium powder and pottery in the resin. At least one of porcelain powder, calcium oxide or zirconium oxide.

In one embodiment, the mold frame includes a bottom plate and at least one side frame portion detachably mounted on a periphery of the bottom plate, and the surface of the bottom plate is adhesive at least in part. In the step (B), the prototype workpiece is adhered to the bottom plate and is received in the machining groove defined by the bottom plate and the side frame portion.

Preferably, the main material of the bottom plate is polyimine.

The effect of the present invention is that during the manufacturing process, the second reversing mold made of the second colloid (for example, rubber) is not bonded to the first reversing mold made of the first colloid (for example, silicone). It is easy to separate and separate between the two without coating the release layer. Therefore, in the case where the prototype workpiece and its prototype structure are micro-mechanisms, the release of the release layer can effectively improve the dimensional accuracy of the second and the rapid mold, and the duplicated workpiece produced by the rapid mold and the original prototype. The dimensional accuracy of the workpieces coincides with each other.

1‧‧‧ prototype artifact

11‧‧‧ top surface

111‧‧‧Prototype structure

12‧‧‧ bottom

2‧‧‧Template

21‧‧‧floor

22‧‧‧ Side frame

23, 23', 23" ‧ ‧ processing slots

3‧‧‧First colloid

4‧‧‧First reversing mould

41‧‧‧ top surface

411‧‧‧First restructured structure

42‧‧‧ bottom

5‧‧‧Second colloid

6‧‧‧Second remanufacturing mould

61‧‧‧ top surface

611‧‧‧Second restructured structure

62‧‧‧ bottom

7‧‧‧ Third colloid

8‧‧‧Quick mold

81‧‧‧ top surface

811‧‧ embossed structure

82‧‧‧ bottom

9‧‧‧Replicating artifacts

S1 to S7‧‧‧ process steps

Other features and advantages of the present invention will be apparent from the detailed description of the preferred embodiments of the accompanying drawings, wherein: FIG. 1(A) through FIG. 1(I) are schematic diagrams illustrating a prior art rapid mold. 2 is a flow chart illustrating a preferred embodiment of the method for manufacturing the rapid mold of the present invention; and FIGS. 3(A) to 3(H) are schematic views of the process for explaining the manufacturing process of the rapid mold of the present invention.

The foregoing and other technical aspects, features and advantages of the present invention will be apparent from the following description of the preferred embodiments.

Referring to Figure 2, a preferred embodiment of the method of manufacturing a rapid mold of the present invention is shown. The production flow of the rapid mold will be described in detail below with reference to the related drawings of FIGS. 2 and 3(A) to 3(H).

Step S1: Referring to FIG. 3(A), first, a prototype workpiece 1 and a mold frame 2 for mold processing must be prepared in advance.

In this embodiment, the prototype workpiece 1 is a micro-mechanism having a size of, for example, a few millimeters, and includes a top surface 11 and a bottom surface 12 on opposite sides, and a plurality of micro-scales (for example, micron-scale) are formed on the top surface 11 thereof. Prototype structure 111. However, depending on the situation, the prototype structure 111 of the prototype workpiece 1 can also be formed on its side or at the same time on the top and side, which is also an embodiment in which the invention can be implemented.

The mold frame 2 includes a bottom plate 21 and a side frame portion 22 detachably mounted on the periphery of the bottom plate 21. The bottom plate 21 and the side frame portion 22 cooperate to define an outwardly opening machining groove 23. However, in the subsequent manufacturing process, the processing groove 23 can also be defined by the side frame portion 22 and the various molds, so that there are different implementations.

In addition, in the embodiment, the main material of the bottom plate 21 of the above-mentioned mold frame 2 is polyimide, and at least part of the surface has adhesiveness, so that the prototype workpiece 1 can be adhered thereon to avoid the prototype workpiece 1 Sliding and offset problems occur during production. Therefore, this step S1 is installed. When the prototype workpiece 1 is in the processing slot 23 of the mold frame 2, the bottom surface 12 of the prototype workpiece 1 is adhered to the bottom plate 21 of the mold frame 2, and the prototype structure 111 located on the top surface 11 of the prototype workpiece 1 is opened outward so that Carry out the subsequent production process.

Step S2: Referring to FIG. 3(B) and FIG. 3(C), after the prototype workpiece 1 is mounted on the mold frame 2, the first colloid 3 not attached to the prototype workpiece 1 can be poured into the mold frame 2. In the groove 23, the first colloid 3 is further solidified into a first turning mold 4. Here, the material of the first colloid 3 is silicone, which is suitable for making a high-precision mold and is easy to be separated from the prototype workpiece 1. After the curing process, the first mold 4 can be formed. The first retreading die 4 includes a top surface 41 and a bottom surface 42 on opposite sides, and it contacts the top surface 41 of the prototype workpiece 1 to correspondingly form a first turn of the prototype structure 111 complementary to the prototype workpiece 1. The structure 411 can be used as an intermediate mold temporarily used in the mold manufacturing process.

Steps S3 and S4: Referring to FIG. 3(C), FIG. 3(D) and FIG. 3(E), after the first remaking mold 4 is completed, the first re-molding mold 4 and the prototype workpiece 1 are firstly taken from the mold. The frame 2 is removed and the first tumbling die 4 is separated from the prototype workpiece 1.

Next, the first retreading mold 4 is installed in the side frame portion 22 such that the bottom surface 42 of the first retreading mold 4 is substantially flush with the bottom end of the side frame portion 22, and the first retreading mold 4 is The first revolving structure 411 is housed in the side frame portion 22 and is open to the outside. Accordingly, the first reshaping mold 4 and the side frame portion 22 can cooperate to define a machining groove 23'.

Subsequently, the second is not linked to the first rewinding mold 4 The colloid 5 is formed in the processing groove 23', and the second colloid 5 is solidified into a second reversing mold 6. Here, the second colloid 5 is made of rubber, is suitable for making a high-precision mold, and is easily separated from the first rewinding mold 4 of the silicone material. After the curing process, the second reversing mold 6 can be formed. The second retreading mold 6 includes a top surface 61 and a bottom surface 62 on opposite sides, and contacts the top surface 61 of the first retreading mold 4 to form a complement to the first retreading mold 4 The second revolving structure 611 of the revolving structure 411 can be similar to the first reshaping mold 4 as an intermediate mold temporarily used in the mold manufacturing process.

Steps S5 and S6: Referring to FIG. 3(E), FIG. 3(F), FIG. 3(G) and FIG. 3(H), after the second remaking mold 6 is completed, the first re-molding mold 4 is firstly used. The second turning mold 6 is removed from the side frame portion 22, and the first turning mold 4 is separated from the second turning mold 6.

Next, the second turning mold 6 is installed in the side frame portion 22, so that the bottom surface 62 of the second turning mold 6 is substantially flush with the bottom end of the side frame portion 22, and the second turning mold 6 is The second reversing structure 611 is housed in the side frame portion 22 and is open to the outside. Accordingly, the second turning mold 6 and the side frame portion 22 can cooperate to define a machining groove 23".

Subsequently, a third colloid 7 not attached to the second reshaping mold 6 is poured into the processing tank 23", and the third colloid 7 is solidified into a rapid mold 8. Here, the third colloid 7 is a metal resin. (ie, resin containing metal powder), suitable for making high-precision molds and easy to separate from the second turning mold 6 of rubber material, after being subjected to a curing process, a rapid mold 8 can be formed. For example, the third The resin part of the colloid 7 can be epoxy resin The metal powder is aluminum powder, and a preferred ratio of the two is 15% (epoxy resin): 85% (aluminum powder). Further, at least one of tantalum powder, ceramic powder, calcium oxide or zirconium oxide may be further added to the third colloid 7 to enhance the structural strength of the rapid mold 8.

The rapid mold 8 made of the third colloid 7 includes a top surface 81 and a bottom surface 82 on the opposite side, and it contacts the top surface 81 of the second turning mold 6, which is correspondingly formed to complement the second reversal. The embossed structure 811 of the second revolving structure 611 of the mold 6. The embossed structure 811 is complementary to the prototype structure 111 of the prototype workpiece 1 in addition to the second tumbling structure 611 of the second retreading mold 6, so that the rapid dies 8 are used as a molding process (for example, hot embossing). The mold of the prototype workpiece 1 can be produced.

After the filling and solidifying forming step of the above-described rapid mold 8 is completed, the rapid mold 8 and the second turning mold 6 can be removed from the side frame portion 22, and finally the two are separated, that is, the manufacture of the rapid mold 8 is completed.

Referring to Fig. 3(H), a comparison diagram of the prototype workpiece 1 and the replica workpiece 9 produced by the rapid mold 8 is shown. The manufacturing method of the present invention can easily separate the molds from each other by selecting the material of the first turning mold 4, the second turning mold 6 and the rapid mold 8 without providing a release layer between the various molds. Therefore, the manufacturing method of the rapid mold 8 proposed by the present invention can improve the dimensional accuracy of the rapid mold 8, avoid the dimensional accuracy error caused by the release layer, and is suitable for the reshaping of the miniature prototype workpiece 1, and can improve the reproduction of the workpiece 9 and the prototype. Since the dimensional accuracy of the workpiece 1 is in good agreement, the object of the present invention can be achieved.

However, it should be particularly noted that although the above manufacturing process is to make the first tumbling die 4 from silicone rubber and to make the second tumbling die 6 from rubber, the manufacturing method of the present invention may also use the rubber to make the first tumbling die. 4, the second remanufactured mold 6 is made of tannin, which is an adjustable technical means, and is not limited to the foregoing description. Further, the materials of the first and second molds 4 and 6 are not limited to silicone rubber or rubber, and are suitable for high-precision mold production and easy to release.

The above is only the preferred embodiment of the present invention, and the scope of the present invention is not limited thereto, that is, the simple equivalent changes and modifications made by the patent application scope and patent specification content of the present invention, All remain within the scope of the invention patent.

S1 to S7‧‧‧ process steps

Claims (9)

A rapid mold manufacturing method for producing a replica workpiece of a prototype workpiece, the surface of the prototype workpiece forming at least one prototype structure, the manufacturing method comprising the steps of: (A) preparing a mold frame, the mold frame Having an outwardly open machining slot; (B) mounting the prototype workpiece in the machining slot of the mold frame, and opening the prototype structure of the prototype workpiece outward, and then injecting a first one that is not linked to the prototype workpiece The colloid is in the processing groove of the mold frame, and the first colloid is solidified into a first turning mold, and the surface of the first turning mold forms at least one first revolving structure complementary to the prototype structure; (C) removing the first mold and the prototype workpiece from the mold frame, and separating the first mold from the prototype workpiece, and then installing the first mold to process the mold In the groove, and opening the first reversing structure of the first casting mold outward, and then pouring a second colloid not attached to the first refining mold into the processing groove of the mold frame, and The second colloid is solidified into a second turn a mold, the surface of the second mold is formed with at least one second turned structure complementary to the first turned structure; and (D) the first and second molds are removed from the mold Moving out of the frame, separating the first turning mold from the second turning mold, and then installing the second turning mold in the processing groove of the mold frame, and making the second turning mold second The flipping structure is opened outward, and then a third colloid not attached to the second refining mold is poured into the processing groove of the mold frame, and the third colloid is solidified into a rapid mold, and the rapid mold is formed. The surface is formed with at least one embossed structure that is complementary to the second revolving structure. The method of manufacturing a rapid mold according to claim 1, wherein after the step (D), a step (E) is further included: the second mold and the rapid mold are removed from the mold frame, and The second reversing mold is separated from the rapid mold. The method of manufacturing a rapid mold according to claim 1, wherein one of the first colloid and the second colloid is silicone, and the other of the first colloid and the second colloid is rubber. The method of manufacturing a rapid mold according to claim 3, wherein the first colloid is silicone and the second colloid is rubber. The method of manufacturing a rapid mold according to claim 1, wherein the third colloid is a resin containing a metal powder. The method of manufacturing a rapid mold according to claim 5, wherein the metal powder is aluminum powder, and the resin is an epoxy resin. The method of manufacturing a rapid mold according to claim 5, wherein the third colloid further comprises at least one of tantalum powder, ceramic powder, calcium oxide or zirconium oxide in the resin. The method of manufacturing a rapid mold according to claim 1, wherein the mold frame comprises a bottom plate and at least one side frame portion detachably mounted on a periphery of the bottom plate, and the surface of the bottom plate is adhesive at least in part In the step (B), the prototype workpiece is adhered to the bottom plate and is received in the machining groove defined by the bottom plate and the side frame portion. A method of manufacturing a rapid mold according to claim 8, wherein the bottom plate The main material is polyimine.