JP2005330142A - Mold for mold forming and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a large number of mold-forming molds, each with a highly precise molding surface and high strength, at a low cost within a short period of time. <P>SOLUTION: A joining member 23 made of glass having a glass yield point lower than the glass transition temperature of the mold main body 21 is placed between a bonding end of a mold substrate 22, which is supported by a substrate base 11, and a glass-made mold main body 21. The mold main body 21 and the joining member 23 are nip-pressed between a master mold 13 and the mold substrate 22 at a molding/joining temperature between the glass transition temperature and the glass yield point of the mold main body 21 to simultaneously perform formation of the mold surface 21a through transferring of a transfer pattern 13a of the master mold 13 to the mold main body 21 and joining of the mold main body 21 and the mold substrate 22 via the joining member 23. Since the joining member 23 has a glass yield point lower than the glass transition temperature of the mold main body 21, it melts at a molding temperature suitable for high-precision forming of the mold main body 21 and forms a favorable, high-strength joint. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a mold for molding and a manufacturing technique thereof, and more particularly to a technique effective when applied to a mold for molding used for molding an optical element or the like.

  For example, molding is effective for mass production of optical elements such as lenses, prisms and filters. By the way, in the production of a mold for molding used for such molding, the cost is high when it is manufactured by machining or the like, and particularly, when a molding surface such as an aspherical surface or a free-form surface is processed. It becomes.

For this reason, for example, as in Patent Document 1, it is conceivable to form a mold forming surface of a mold by press transfer from a master mold.
Further, in Patent Document 2, a molding die body made of glass press-molded in the hot state, a molding die body, and a joined body (support member) made of metal or ceramics having substantially the same linear expansion coefficient. A configured optical element molding die is disclosed. That is, simultaneously with the heating and pressing for forming the molding surface of the molding die body, the molding die body and the irradiation member are also joined.

  However, in general, there is a difference between the temperature at which the surface accuracy of the molding surface of the molding die body made of glass can be obtained and the temperature at which the molding die body can be joined to a supporting member such as metal. When forming the molding surface of the molding die body and joining with the support member at the same time, forming the molding surface with high accuracy in the molding die body and improving the molding die body and the support member There is a technical problem that it is difficult to obtain a high bonding strength at the same time.

That is, in order to maintain the transfer accuracy of the molding surface of the molding die body made of glass, it is necessary to control the temperature range from the glass transition point to the glass yield point, which is plastically deformed only by external force (transfer force), On the other hand, in order to obtain good bonding strength with a metal or the like, it is necessary to heat to a temperature range with high fluidity exceeding the glass yield point.
Japanese Patent Laid-Open No. 11-217227 Japanese Patent Laid-Open No. 2-102136

An object of the present invention is to provide a mold for molding with low cost, high accuracy of a molding surface and high strength.
Another object of the present invention is to provide a manufacturing method capable of supplying a large amount of mold forming molds with high accuracy and high strength at a low cost in a short period of time.

  According to a first aspect of the present invention, there is provided a mold main body made of a first material exhibiting a glass transition behavior and having a molding surface, a mold base supporting the mold main body, and between the mold main body and the mold base. And a joining member made of a second material having a glass transition behavior different from that of the first material.

  According to a second aspect of the present invention, there is provided a mold main body made of a first material exhibiting a glass transition behavior and having a molding surface, a mold base supporting the mold main body, and between the mold main body and the mold base. And a joining member made of a second material having a glass yield point temperature lower than the glass transition temperature of the first material.

  According to a third aspect of the present invention, there is provided a mold main body made of a first material exhibiting a glass transition behavior and having a molding surface, a mold base supporting the mold main body, and between the mold main body and the mold base. And a joining member made of a second material having a glass softening point temperature lower than the glass transition temperature of the first material.

  According to a fourth aspect of the present invention, there is provided a mold main body made of a first material exhibiting a glass transition behavior and having a molding surface, a mold base supporting the mold main body, and between the mold main body and the mold base. And a joining member made of a second material of metallic glass whose glass transition temperature is lower than the glass transition temperature of the first material.

A fifth aspect of the present invention is a method for manufacturing a mold for molding, wherein a mold molding surface is transferred and formed by press molding using a master mold,
A step of sandwiching a joining member made of a second material exhibiting a glass transition behavior different from that of the first material between a mold body made of the first material exhibiting glass transition behavior and a mold base material supporting the mold body. When,
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding is provided.

A sixth aspect of the present invention is a method for producing a mold for molding, wherein the mold molding surface is transferred and formed by press molding using a master mold,
Between the mold body made of the first material exhibiting the glass transition behavior and the mold base material supporting the mold body, the glass yield point temperature is made of the second material lower than the glass transition temperature of the first material. A step of sandwiching the joining member;
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding is provided.

A seventh aspect of the present invention is a method for producing a mold for molding, wherein a mold molding surface is transferred and formed by press molding using a master mold,
Between a mold body made of a first material exhibiting glass transition behavior and a mold substrate supporting the mold body, the glass softening point temperature is made of a second material lower than the glass transition point temperature of the first material. A step of sandwiching the joining member;
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding is provided.

An eighth aspect of the present invention is a method for producing a mold for molding, wherein the mold molding surface is transferred by press molding using a master mold,
A second material of metallic glass having a glass transition temperature lower than a glass transition temperature of the first material between a mold body made of a first material exhibiting a glass transition behavior and a mold substrate supporting the mold body. A step of sandwiching a joining member comprising:
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding is provided.

  According to the present invention described above, for example, the glass yield point temperature, the glass softening point temperature or the glass transition temperature of the second material constituting the joining member is lower than the glass transition temperature of the first material constituting the mold body. The first and second materials are selected so that the heating temperature (processing temperature) when forming and joining are collectively performed is higher than the glass transition temperature of the first material, and the glass of the first material. Set to a value lower than the yield point temperature.

  Then, the die body, the joining member, and the die base material are collectively clamped to transfer the molding surface of the die body and to join the die base material, so that the joining member flows at this processing temperature. And a high bonding strength is obtained between the mold base and the mold body, and the glass forming point temperature of the first material is higher than the glass transition temperature of the first material on the molding surface of the mold body. Since the heating is performed at a lower processing temperature, the mold shape can be transferred from the master mold to the molding surface with high accuracy.

  Further, when metal glass is used as the second material constituting the joining member, the temperature range of the supercooled liquid region includes the temperature range from the glass transition temperature of the first material to the glass yield point temperature. By selecting the type of glass of the first material and the type of metal glass of the second material, the same effect as described above can be obtained.

According to the present invention, it is possible to obtain an effect that a mold for molding can be provided at low cost, with high accuracy of a molding surface and high strength.
Further, it is possible to supply a large amount of mold forming molds with high accuracy and high strength at a low cost in a short period of time.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic cross-sectional view showing an example of the configuration and operation of a mold manufacturing apparatus in which a method for manufacturing a mold for molding according to an embodiment of the present invention is performed, in the order of steps.
The mold manufacturing apparatus 10 of the present embodiment includes a base material base 11, a holder 12, a master mold 13, and a press shaft 14. Further, a heating furnace (not shown) is provided at a position surrounding the base material base 11 and the master die 13 so that the base material base 11 and the master die 13 can be heated to a predetermined temperature.

The base material base 11 is provided with a holding hole 11a in the axial direction, and the mold base material 22 is accommodated in the holding hole 11a with the joint end portion facing upward. A cylindrical holder 12 is disposed so as to surround the joint end of the mold base 22.
A plate-shaped joining member 23 and a mold body 21 are placed in order from the bottom on the joining end of the mold base 22 surrounded by the holder 12.

A master die 13 is disposed at a position facing the base material base 11, and an arbitrarily uneven transfer pattern 13 a is formed on the surface of the master die 13 facing the base material base 11, that is, the die body 21. ing.
The mold base 22 is made of, for example, a commercially available mold material K1 for molds or a commercially available tool steel K2 having physical properties as shown in FIG. Since the outer peripheral portion of the mold base 22 is important as a positioning reference surface (impact surface 22a) for the entire mold 20 obtained as described later, high-precision finishing is performed.

  The mold body 21 is made of a commercially available glass material G3, a commercially available glass material G4, or a commercially available glass material G5 (first material) having physical properties as shown in the lower part of FIG. FIG. 2B is composed of a commercially available glass material G1 or a commercially available glass material G2 (second material) having physical properties as exemplified on the upper side.

  That is, FIG. 3 shows a temperature-elongation characteristic curve of the glass material used for the mold body 21 and the glass material used for the bonding member 23. In the present embodiment, the bonding member 23 is made of the glass. A material having a yield point At temperature lower than the glass transition point Tg of the mold body 21 is selected and used. The molding temperature is set to a temperature between the glass transition point Tg and the glass deformation point At in the mold body 21.

  Hereinafter, an example of the operation of the method for manufacturing the mold for molding according to the present embodiment will be described. First, as shown in FIG. 1A, the mold base 22 is loaded into the holding hole 11a of the base 11 and the holder 12 is set. Next, the joining member 23 and the mold body 21 are placed in order on the joining end of the mold base 22.

  Thereafter, as shown in FIG. 1B, in a heating furnace (not shown), the base material base 11, the die base material 22, the joining member 23, the die body 21 and the master die 13 are set to a predetermined molding / joining temperature T0 (for example, When the mold body 21 is a commercially available glass material G3 or a commercially available glass material G4, it is heated to 530 ° C. to 540 ° C. or 560 ° C. in the case of a commercially available glass material G5), and the master die 13 driven by the press shaft 14 is lowered. Then, the joining member 23 and the mold body 21 are clamped between the mold base 22 and the master mold 13 (for example, when the diameter of the mold base 22 is 7 mm, the thrust of the press shaft 14 is 200 kgf).

  At this time, the mold body 21 accurately follows the transfer pattern 13a of the master mold 13 by setting the molding / joining temperature T0 between the glass transition point Tg of the mold body 21 and the glass yield point At. As a result of plastic deformation, the mold surface 21a to which the irregularities of the transfer pattern 13a are transferred in reverse is formed. At the same time, in the joining member 23, the molding / joining temperature T0 is higher than the glass yield point At, so that the fluidity is improved and the joint strength is infiltrated into the fine irregularities on the joining end surfaces of the mold body 21 and the mold substrate 22. Large and good joints are formed.

  That is, when the molding of the mold surface 21a by the master mold 13 and the joining of the mold body 21 and the mold base 22 are performed at once, the shape of the mold mold surface 21a by the master mold 13 in the mold body 21 is high-precision. It is possible to achieve both the transfer and the improvement of the bonding strength between the mold main body 21 and the mold base 22 by the bonding member 23.

  Thus, after the molding / joining is completed, as shown in FIG. 1C, the master mold 13 is raised and separated from the mold main body 21 as shown in FIG. 1C, and further, as shown in FIG. 11. Disassemble the holder 12 and take out the mold 20 in which the mold body 21 and the mold base 22 are integrally bonded via the bonding member 23.

  In this state, around the upper end portion of the mold body 21, there is a burr or the like formed by spreading a part of the mold body 21 in the gap between the holder 12 and the master mold 13 during molding. By performing a finishing process for removing the burrs and the like in the secondary process, a completed mold 20 is obtained as shown in FIG.

  By repeating the process of FIG. 1A to FIG. 1E in which the molding of the mold mold surface 21a of the mold main body 21 and the bonding of the mold main body 21 and the mold base material 22 are performed collectively, It is possible to produce a large number of molds 20 having a precise mold surface 21a and a high bonding strength between the mold body 21 and the mold base 22 in a short time.

  FIG. 2C shows an experimental result of the method for manufacturing the mold for molding according to the present embodiment. In this case, the molding / joining temperature T0 is set to 530 ° C., a commercially available glass material G3 is used as the mold body 21, a commercially available glass material G2 or a commercially available glass material G1 is used as the joining member 23, and a commercially available mold base 22 is used. An example using a mold material K1 or a commercially available tool steel K2 is shown.

No abnormality is observed in the joint portion between the mold main body 21 and the mold base 22 when the mold 20 that is a combination of these is rapidly cooled or slowly cooled, and the injection using the mold 20 is performed. In the molding, the optical element could be molded with good accuracy.
Next, an example in which metallic glass is used as the mold base 22 will be shown. That is, the metallic glass G7 (second material) having physical properties shown in FIG. 4A is used as the mold base 22, and the commercially available glass material G6 (first material) having physical properties shown in FIG. An example in which a commercially available mold material K1 is used as the mold base 22 is shown.

  In this case, the glass transition temperature (transition point) Tg (= 435 ° C.) of the metallic glass G 7 constituting the joining member 23 is higher than the glass transition point Tg (= 458 ° C.) of the commercially available glass material G 6 constituting the mold body 21. The value is low. Further, a molding / joining temperature T0 (= 470 ° C.) described later is lower than the glass crystallization temperature Tx of the metal glass G7.

That is, as illustrated in the diagram of FIG. 5, the supercooled liquid region of the metal glass G7 has a temperature relationship in which the glass transition point Tg of the commercial glass material G6, the molding / joining temperature T0, and the like are included.
And as shown in FIG.4 (c), with this joining member 23 of the metal glass G7, the mold main body 21 of the commercial glass material G6 and the mold base material 22 of the commercial mold material K1 are formed at a molding / joining temperature of 470 ° C. As a result of molding / joining at T0, good joining results were obtained.

  That is, when molding and joining using the mold manufacturing apparatus 10, when heated to the molding / joining temperature T0 (= 470 ° C.), the metallic glass G7 of the mold base 22 becomes a supercooled liquid region and the mold base 22 and the mold The mold body 21 infiltrates unevenness of the joint surface of the main body 21 to form a good joint portion having high joint strength, and the mold main body 21 is in a plastic state suitable for transfer, and a high-precision mold following the transfer pattern 13a of the master mold 13 The mold surface 21a is transferred and formed.

That is, highly accurate transfer of the mold surface 21a in the mold body 21 and good bonding with high bonding strength by the bonding member 23 between the mold body 21 and the mold substrate 22 can be achieved simultaneously.
6A to 6D are schematic cross-sectional views showing the configuration and operation of a mold manufacturing apparatus 30 which is a modification of the mold manufacturing apparatus 10 of the present embodiment in the order of steps.

  In this case, as shown in FIG. 6A, the mold base 22-1 having a flange-like lower end is inserted into the holding hole 31a of the base 31 and the holder 32 is configured to be elongated in the axial direction. The entire master die 33 with the transfer pattern 33a formed therein is inserted without any gaps while surrounding the joining end portion of the mold base 22-1 and the joining member 23 and the die body 21 placed on the joining end portion. It has a configuration.

  As a result, as shown in FIG. 6B, the master die 33 is pressed by the press shaft 14 in the heating state at the molding / joining temperature T0, and the die body 21 and the die base material 22-1. When clamping the joining member 23, the transfer pattern 33 a is transferred from the master die 33 to the die body 21 as the mold die surface 21 a, and at the same time, the die body 21 and the die base material 22-1 are joined via the joining member 23. Is done. At this time, no burrs are generated in the mold main body 21 pressed by the master mold 33 that fits in the holder 32 without a gap.

Then, by performing cooling and mold release as shown in FIG. 6C, a mold 20 as shown in FIG. 6D is obtained. In this case, secondary processing such as deburring of the mold body 21 is not necessary.
FIGS. 7A to 7C are schematic cross-sectional views showing a method for manufacturing a mold for molding which is another embodiment of the present invention in the order of steps.

  In this case, it is different from the case of FIG. 1 in that the powder or granular joining member 23a is distributed on the mold base 22 and supplied almost uniformly. As a result, the powdered or granular joining member 23a is melted and uniformly distributed between the joining surfaces of the mold body 21 and the mold base 22 at the time of molding / joining, which is caused by variations in the thickness of the joining member, displacement, and the like. Thus, problems such as the mold body 21 being inclined with respect to the mold base material 22 during molding / joining are eliminated, and the mold mold surface 21a of the mold body 21 can be stably molded.

FIGS. 8A to 8C are schematic cross-sectional views showing a method of manufacturing a mold for molding which is still another embodiment of the present invention in the order of steps.
In the example of FIG. 8, a positioning groove 22b is formed at the center of the joining end surface of the mold base 22 as shown in FIG. 9A, and the position of the positioning groove 22b as shown in FIG. 9A. The spherical joining member 23b is disposed on the mold body 21 and the mold body 21 is placed thereon.

  When molding / joining is performed by applying pressure as shown in FIG. 8B, the spherical joining member 23b is pressed by the clamping force between the mold body 21 and the mold substrate 22, and the mold body 21 and the mold substrate. It spreads in a self-aligned manner so that the balance of the clamping pressure of 22 is uniform within the joint surface, and is uniformly distributed in the gap between the two. As a result, it is possible to reliably prevent problems such as the mold body 21 being joined to the mold substrate 22 in an inclined state. In addition, air entrainment on the joint surface is eliminated, and a joint portion having a relatively thin thickness is formed by appropriately setting the size of the spherical joint member 23b according to the area of the joint surface of the mold base 22. You can also

Further, since the single spherical joining member 23b is convenient to handle, there are advantages such as easy transportation, supply to the joining portion, and automation of positioning.
The number of spherical bonding members 23b is not limited to one, and a plurality of spherical bonding members 23b may be evenly arranged on the bonding surface of the mold base 22 as shown in FIG. In this case, it goes without saying that the plurality of positioning grooves 22b are formed uniformly at the arrangement position.

BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic sectional drawing which shows an example of a structure and operation | movement of a type | mold manufacturing apparatus with which the manufacturing method of the shaping | molding die which is one embodiment of this invention is implemented in order of a process. (A)-(c) is a figure which shows the physical property of the raw material used for the manufacturing method of the shaping | molding die which is one embodiment of this invention, and the experimental result of joining. It is a diagram which shows the temperature-elongation characteristic curve of the glass material used for the manufacturing method of the shaping | molding die which is one embodiment of this invention. (A)-(c) is a figure which shows the physical property of the raw material used for the manufacturing method of the shaping | molding die which is one embodiment of this invention, and the experimental result of joining. It is a diagram which shows the temperature-elongation characteristic curve of the glass material used for the manufacturing method of the shaping | molding die which is one embodiment of this invention. (A)-(d) is a schematic sectional drawing which shows the structure and operation | movement of the modification of the type | mold manufacturing apparatus which is one embodiment of this invention in order of a process. (A)-(c) is a schematic sectional drawing which shows the manufacturing method of the shaping | molding die which is other embodiment of this invention in order of a process. (A)-(c) is a schematic sectional drawing which shows the manufacturing method of the shaping | molding die which is further another embodiment of this invention in order of a process. (A) And (b) is a top view which shows the example of arrangement | positioning of the joining member in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Type | mold manufacturing apparatus 11 Base material base 11a Holding hole 12 Holder 13 Master type | mold 13a Transfer pattern 14 Press axis | shaft 20 Mold shaping | molding die 21 Mold main body 21a Mold die surface 22 Joining member 23a Powdered or granular joining member 23b Spherical joining member 30 Mold manufacturing apparatus 31 Base base 31a Holding hole 32 Holder 33 Master mold 33a Transfer pattern G1 to G6 Commercial glass material G7 Metallic glass K1 Commercial mold material K2 Commercial tool steel T0 Molding / joining temperature Tg Glass transition point At Glass yield point Tx Glass crystallization temperature

Claims (16)

  A mold body made of a first material exhibiting glass transition behavior and having a molding surface, a mold base material for supporting the mold body, and the first material interposed between the mold body and the mold base material A molding die characterized by integrally joining a joining member made of a second material exhibiting different glass transition behavior.   A mold main body made of a first material exhibiting glass transition behavior and having a molding surface, a mold base supporting the mold main body, and interposed between the mold main body and the mold base, the glass yield point temperature being A mold for molding, wherein a joining member made of a second material lower than the glass transition temperature of the first material is integrally joined.   A mold main body made of a first material exhibiting glass transition behavior and having a molding surface, a mold base supporting the mold main body, and interposed between the mold main body and the mold base, the glass softening point temperature being A mold for molding, wherein a joining member made of a second material lower than the glass transition temperature of the first material is integrally joined.   A mold body made of a first material exhibiting glass transition behavior and having a molding surface, a mold substrate supporting the mold body, and interposed between the mold body and the mold substrate, the glass transition temperature is A molding die characterized by integrally joining a joining member made of a second material of metallic glass lower than the glass transition temperature of the first material.   The mold for molding according to any one of claims 1 to 4, wherein the first material is made of glass or metal glass.   The mold for molding according to claim 1, wherein the second material is made of glass or metal glass. A method for producing a mold for molding, wherein a molding surface is transferred by press molding using a master mold,
A step of sandwiching a joining member made of a second material exhibiting a glass transition behavior different from that of the first material between a mold body made of the first material exhibiting glass transition behavior and a mold base material supporting the mold body. When,
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding, comprising: A method for producing a mold for molding, wherein a molding surface is transferred by press molding using a master mold,
Between the mold body made of the first material exhibiting the glass transition behavior and the mold base material supporting the mold body, the glass yield point temperature is made of the second material lower than the glass transition temperature of the first material. A step of sandwiching the joining member;
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding, comprising: A method for producing a mold for molding, wherein a molding surface is transferred by press molding using a master mold,
Between a mold body made of a first material exhibiting glass transition behavior and a mold substrate supporting the mold body, the glass softening point temperature is made of a second material lower than the glass transition point temperature of the first material. A step of sandwiching the joining member;
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding, comprising: A method for producing a mold for molding, wherein a molding surface is transferred by press molding using a master mold,
A second material of metallic glass having a glass transition temperature lower than a glass transition temperature of the first material between a mold body made of a first material exhibiting a glass transition behavior and a mold substrate supporting the mold body. A step of sandwiching a joining member comprising:
The master mold is brought into contact with the mold main body, and the mold main body and the joining member are clamped between the master mold and the mold base, thereby transferring and forming the molding surface on the mold main body. Bonding the mold body, the joining member, and the mold substrate;
A method for producing a mold for molding, comprising:   8. The method for manufacturing a mold for molding according to claim 7, wherein the first material is made of glass or metal glass.   The method for producing a mold for molding according to claim 11, wherein the second material is made of glass or metal glass.   The method for manufacturing a mold for molding according to any one of claims 7 to 12, wherein the joining member is a powder made of the second material.   The method for manufacturing a mold for molding according to any one of claims 7 to 12, wherein the joining member is made of the spherical second material.   The method for manufacturing a mold for molding according to any one of claims 7 to 12, wherein the joining member is made of the plate-like second material.   The method for manufacturing a mold for molding according to claim 14, wherein a concave portion for positioning the second material having a spherical shape is formed in a contact portion of the mold base with the joining member.

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