【０００９】
さらに、本発明の請求項３の射出成形用金型の製造方法は、微細な凹凸形状を有する成形品を成形するための射出成形用金型の製造方法であって、成形品に要求される微細凹凸面を反転した微細凹凸面を有するマスター型を作製し、マスター型の微細凹凸面に電鋳加工して電鋳型を作製した後、電鋳型をマスター型から離型して射出成形用金型とする射出成形用金型の製造方法において、射出成形用金型に要求される凸部の高さに相当する凹部をマスター型に加工する際、所望の深さより少なくとも凹部の底部に残ることが推測される未加工部の高さ分以上に深く凹部を加工し、この凹部を反転させた電鋳型の凸部が射出成形用金型に要求される凸形状の高さとなるまで、電鋳型の凸部端面を除去加工することを特徴とする。
さらに、本発明の射出成形用金型の製造方法は、微細な凹凸形状を有する成型品を成形するための射出成形用金型の製造方法であって、成型品に要求される微細凹凸面を反転した微細凹凸面を有するマスター型を切削バイトにて切削加工して作製し、マスター型の微細凹凸面に電鋳加工を施して電鋳型を作製した後、電鋳型をマスター型から離型して射出成形用金型を得る射出成形用金型の製造方法において、マスター型に凹部を切削加工する際、その凹部を射出成形用金型に要求される凸形状の高さに相当する所望の深さより少なくとも切削バイトのノーズＲ寸法以上深く切削加工し、前記凹部を反転させて電鋳型に形成された凸部が射出成形用金型に要求される凸形状の高さとなるまで前記凸部を切削加工することを特徴とする。
さらに、本発明の射出成形用金型の製造方法は、微細な凹凸形状を有する成型品を成型するための射出成形用金型の製造方法であって、成型品に要求される微細凹凸面を反転した微細凹凸面を有するマスター型をエッチングにより作製し、マスター型の微細凹凸面に電鋳加工を施して電鋳型を作製した後、電鋳型をマスター型から離型して射出成形用金型を得る射出成形用金型の製造方法において、マスター型に凹部を形成する際、その凹部を射出成形用金型に要求される凸形状の高さに相当する所望の深さより少なくとも凹部底面に形成されるＲ形状の高さ分だけ深く形成し、前記凹部を反転させて電鋳型に形成された凸部が射出成形用金型に要求される凸形状の高さとなるまで前記凸部を切削加工することを特徴とする。 [0009]
Furthermore, the manufacturing method of an injection molding mold of claim 3 of the present invention is a manufacturing method of an injection molding mold for molding a molded product having a fine uneven shape, and includes the steps of: preparing a master mold having a fine uneven surface that is the inverse of the fine uneven surface required for the molded product; electroforming the fine uneven surface of the master mold to produce an electroformed mold; and then releasing the electroformed mold from the master mold to form an injection molding mold, wherein, when machining a recess in the master mold corresponding to the height of the convex portion required for the injection molding mold, the recess is machined to a depth that is at least equal to the height of the unmachined portion that is expected to remain at the bottom of the recess, deeper than the desired depth, and removing the end faces of the convex portions of the electroformed mold until the convex portions of the electroformed mold, which is the inverse of this recess, have the height of the convex shape required for the injection molding mold.
Furthermore, the method for manufacturing an injection molding mold of the present invention is a method for manufacturing an injection molding mold for molding a molded product having a finely uneven shape, and includes cutting a master mold having a finely uneven surface that is the inverse of the finely uneven surface required for the molded product using a cutting tool, electroforming the finely uneven surface of the master mold to produce an electroformed mold, and then releasing the electroformed mold from the master mold to obtain the injection molding mold, and is characterized in that when cutting a recess into the master mold, the recess is cut to a depth that is at least the nose R dimension of the cutting tool deeper than the desired depth corresponding to the height of the convex shape required for the injection molding mold, and the recess is inverted and the convex portion formed in the electroformed mold is cut to the height of the convex shape required for the injection molding mold.
Furthermore, the method for manufacturing an injection molding mold of the present invention is a method for manufacturing an injection molding mold for molding a molded product having a finely textured shape, and includes the steps of: producing by etching a master mold having a finely textured surface that is the inverse of the finely textured surface required for the molded product; electroforming the finely textured surface of the master mold to produce an electroformed mold; and then releasing the electroformed mold from the master mold to obtain the injection molding mold, and is characterized in that when forming a recess in the master mold, the recess is made deeper by at least the height of the R-shape to be formed on the bottom of the recess than the desired depth equivalent to the height of the convex shape required for the injection molding mold, and then inverting the recess and cutting the convex portion formed in the electroformed mold until the convex portion has the height of the convex shape required for the injection molding mold.
【００１１】
請求項２の発明によれば、マスター型に微細な凹凸形状を形成する際、凹部の底面に形成されるＲ部が、マスター型を電鋳加工して前記凹凸形状を反転した電鋳型の表面に転写される。転写された凸部のＲ部は切削加工で除去されるとともに表面粗さも取り除かれ、精度および表面粗さが向上させた凹凸形状を有する射出成形用金型が得られる。従って、請求項１および請求項２の発明によれば、射出成形用金型は、成型品の微細凹凸形状を形成するための前記金型の転写部における微細凹凸面の凸部端面が切削加工あるいは研削加工が施された加工面であり、前記微細凹凸面の凹部が前記マスター型の表面を転写した転写面であることを特徴とする射出成形用金型となる。 [0011]
According to the invention of claim 2, when forming a fine uneven shape in the master mold, the rounded portions formed on the bottom surfaces of the recesses are transferred to the surface of an electroformed mold, which is an inverse of the uneven shape obtained by electroforming the master mold. The rounded portions of the transferred protrusions are removed by cutting, and the surface roughness is also removed, resulting in an injection molding mold having an uneven shape with improved precision and surface roughness. Therefore, according to the inventions of claims 1 and 2, the injection molding mold is characterized in that the end faces of the convex portions of the fine uneven surface in the transfer portion of the mold for forming the fine uneven shape of the molded product are machined surfaces that have been subjected to cutting or grinding, and the recesses of the fine uneven surface are transfer surfaces to which the surface of the master mold is transferred.
【００１２】
請求項３、請求項５及び請求項６の発明によれば、微細な凹凸形状を加工されたマスター型の凹凸面に電鋳加工を施して前記凹凸形状を転写させた電鋳型を得る。この電鋳型の凹凸形状はマスター型の凹凸形状がそのまま反転されたものであり、マスター型の凹凸形状を加工した時の表面粗さや凹部底辺のＲ形状未加工部は、電鋳型の凹凸形状の表面粗さや凸部先端角部のＲ形状として形成される。そして、電鋳型の凹凸形状のうち凸部のみを切削加工して凸部端面を除去することでＲ形状未加工部や表面粗さを取り除き、シャープな凹凸形状に仕上げる。[0012]
According to the inventions of claims 3, 5, and 6 , an electroformed mold is obtained by electroforming the concave-convex surface of a master mold machined with a fine concave-convex shape, transferring the concave-convex shape. The concave-convex shape of this electroformed mold is a direct inversion of the concave-convex shape of the master mold, and the surface roughness and unprocessed rounded portions at the bottoms of the recesses when the concave-convex shape of the master mold is machined are formed as the surface roughness of the concave-convex shape of the electroformed mold and the rounded corners at the tips of the convex portions. Then, only the convex portions of the concave-convex shape of the electroformed mold are machined to remove the end faces of the convex portions, thereby removing the unprocessed rounded portions and surface roughness and resulting in a sharp concave-convex shape.