WO2015194608A1

WO2015194608A1 - Molding, molding die, and method for producing molding die

Info

Publication number: WO2015194608A1
Application number: PCT/JP2015/067524
Authority: WO
Inventors: 水金貴裕; 森本智之
Original assignee: コニカミノルタ株式会社
Priority date: 2014-06-18
Filing date: 2015-06-17
Publication date: 2015-12-23
Also published as: JPWO2015194608A1

Abstract

This molding (10) has a top surface (10a) which is a macroscopically mirror-surface-shaped molding surface, a localized area on the top surface (10a) has a decorative part (10d) formed by a concavity, the amount of the height level difference in the decorative part (10d) is less than half of a concave-convex component including a shape component that is symmetric from the top surface (10a), and the stress of setting shrinkage when the molding (10) is molded is therefore dispersed through the entire top surface (10a) without concentrating in a specific portion, and because glass as the molding material is smoothly released from the die, a molding (10) free of cloudiness and cracks can be obtained even if the decorative part (10d) is provided to a transparent material.

Description

Molded product, mold and method for producing mold

The present invention relates to a molded product that is formed of a transparent material and has a decorative portion such as a character, pattern, or pattern on its surface, a molding die for manufacturing the molded product, and a method for manufacturing the molding die.

When manufacturing a decorative panel with irregularities (decorations) representing characters, patterns, designs, etc. on the surface of a transparent material, a decorative transfer part with the desired decoration part reversed is used. It is necessary to provide the mold. Here, the flatter the surface roughness of the mold, the higher the transparency of the molded product to be molded. Therefore, it is necessary to finish the entire transfer surface of the mold to a mirror surface. For example, when a concave structure having a decorative portion on the surface of a resin molded product is processed by laser engraving, the surface roughness of the processed surface is deteriorated and becomes cloudy. However, in the method for manufacturing a decorative panel described in Patent Document 1, a character, a pattern, a pattern, or the like formed with ink is printed on a mold, and the unevenness of the ink is transferred to an acrylic resin or the like, thereby forming a molded product. The decorative part is formed on the surface of the surface without clouding.

In mold molding, the melted molding material is poured into a molding die, and after the decorative transfer portion of the molding die is transferred, the molding material is cured. However, if the decorative transfer part is provided on the transfer surface of the mold, the molding material cannot interfere freely with the mold at the decorative transfer part and cannot be shrunk freely. concentrate. This stress causes a problem that the molded material after curing cannot be released from the mold or that the decorative part may be chipped at the time of release. When a molding material such as glass that is brittle and easily chipped is used, chipping due to this stress tends to be a problem. In order to prevent chipping, a taper is provided on the decorative transfer part of the mold to make it easy to release, but when the decoration is small, the taper also makes the decoration small and the visibility deteriorates. There is. The decorative part can be formed by using the unevenness of the ink so that white turbidity does not occur in the production method described in Patent Document 1, but the ink is printed on a film-like printing substrate, or the printing substrate is formed after molding The trouble of peeling off from the acrylic resin occurs. Further, Patent Document 1 does not describe a problem related to the lack of the decorative portion.

JP 2008-55761 A

The object of the present invention is to provide a molded product that is free from cloudiness and chipping even when a decorative portion such as a character, pattern, or pattern is provided on the surface of a transparent material.

Moreover, an object of the present invention is to provide a mold for manufacturing the above-mentioned molded product and a method for manufacturing the mold.

In order to solve the above problems, the molded product according to the present invention has a macroscopically mirror-shaped molding surface in a predetermined region, and has a concave or convex shape in a local region on the molding surface within the predetermined region. The amount of the step of the decorative portion is smaller than half of the uneven component taking into account the symmetrical shape component from the molding surface. Here, the macroscopic shape means that the surface is uneven when viewed microscopically, but is specular when the entire predetermined region is observed. The symmetrical shape component means an approximate curve having fine irregularities in the cross section in the predetermined region.

According to the molded product described above, the level difference of the decorative portion is minute when viewed from the entire molding surface, and the main component of the irregularities on the molding surface is a mirror-like irregular component, that is, a swell component. Therefore, the stress at the time of curing shrinkage is distributed over the entire molding surface and does not concentrate on a specific portion, and the molding material can be released smoothly. Thereby, even if it provides a decoration part in a transparent material, it becomes a molded product without cloudiness and a chip. In particular, even when the molding material is a brittle material such as glass, the decorative portion is not chipped, and the edge of the decorative portion stands, so that even if the step amount of the decorative portion is small, it can be clearly recognized.

In a specific aspect or viewpoint of the present invention, the following conditional expression is satisfied when the step of the decorative portion is Δ and the PV value of the surface shape of the molding surface is A1 in the molded product.
A1 / 2> Δ

In another aspect of the present invention, the step amount of the decorative portion is 1 μm or less. In this case, it is possible to reliably prevent the chipping from occurring at the step portion that forms the contour of the decorative portion.

In yet another aspect of the present invention, the molded product is formed of glass.

In order to solve the above-mentioned problems, the mold according to the present invention has a macroscopic mirror-like transfer surface in a predetermined region, and has a concave or convex shape in a local region on the transfer surface within the predetermined region. The amount of the step of the decorative transfer portion is smaller than half of the uneven component taking into account the symmetrical shape component from the transfer surface.

According to the above mold, the step amount of the decorative transfer portion is minute when viewed from the entire transfer surface, and the main component of the unevenness of the transfer surface is a mirror-like uneven component. Therefore, the stress at the time of curing shrinkage is dispersed over the entire molding surface of the molded product and does not concentrate on a specific portion, and the molding material can be released smoothly.

In a specific mode or aspect of the present invention, the following conditional expression is satisfied when the step of the decorative transfer portion is Δ and the PV value of the surface shape of the transfer surface is A1 in the mold.
A1 / 2> Δ

In another aspect of the present invention, the transfer surface has a release treatment layer. In this case, if the release treatment layer is peeled and re-formed, a molding die corresponding to the shape of the decorative portion can be obtained with one base material, and the cost can be reduced.

In still another aspect of the present invention, the thickness of the release treatment layer is larger than the step amount of the decorative transfer portion. In this case, the base material of the mold after the release treatment layer is peeled can be in a state where there is no decoration transfer portion.

In order to solve the above-described problems, a manufacturing method of a mold according to the present invention includes a mirror surface processing step for macroscopically processing a predetermined region of a transfer surface of the mold into a mirror surface, and a transfer in the predetermined region after the mirror surface processing step. A mask forming step for forming a mask pattern corresponding to the decoration transfer portion on the surface; and a decoration processing step for etching the exposed portion of the mask pattern by dry etching to form the decoration transfer portion.

According to the above method for manufacturing a mold, by simply processing the entire transfer surface into a mirror surface before forming the decorative transfer portion, it is possible to easily obtain a molded surface having a concavo-convex component larger than the step amount of the decorative transfer portion. Can do. In addition, for example, by using a gas cluster ion beam, the decorative portion transfer portion can process a surface with a flat surface roughness, and has a mirror surface property equal to or higher than the mirror surface property obtained in the mirror surface processing step. Obtainable. Thereby, the mirror surface state can be maintained over the entire transfer surface.

In a specific embodiment or aspect of the present invention, a gas cluster ion beam is used in dry etching in the above-described mold manufacturing method. In this case, a minute processing amount of 1 μm or less can be aimed at with high accuracy depending on the irradiation time of the gas cluster ion beam.

Another aspect of the present invention includes a layer forming step of forming a release treatment layer on the mirror-like lower ground before the mask forming step after the mirror finishing step. In this case, the decorative transfer portion can be formed on the release treatment layer.

In still another aspect of the present invention, the transfer surface is mirror-finished by mechanical polishing in the mirror-finishing step.

1A is a conceptual perspective view for explaining a molded product according to the first embodiment of the present invention, and FIG. 1B is a conceptual cross-sectional view of the molded product shown in FIG. 1A. It is an expanded sectional view explaining the shaping | molding die for shape | molding the molded article of FIG. 1A. FIG. 3A is a conceptual diagram for explaining the surface shape of the molded article in a specific cross section, FIG. 3B is a conceptual diagram for explaining the surface shape of FIG. 3A excluding the spherical component, and FIG. It is a figure explaining further enlarging the surface shape of 3B. FIG. 4A is a cross-sectional view illustrating the shape characteristics of the molded product, and FIG. 4B is a cross-sectional view of a transfer surface for molding the molded product shown in FIG. 4A. 5A and 5B are diagrams illustrating a molding apparatus used for manufacturing a molded product according to the first embodiment. It is a figure explaining the etching apparatus used for manufacture of the shaping | molding die shown in FIG. It is an expanded sectional view explaining the shaping | molding die for shape | molding the molded product which concerns on 2nd Embodiment.

[First Embodiment]
With reference to FIG. 1A and 1B etc., the molded article which concerns on 1st Embodiment of this invention is demonstrated.

The molded product 10 is a transparent or light transmissive member formed by press molding of glass or the like. Although the molded product 10 is a plate-shaped member having a rectangular outline, as shown in FIG. 1B, the center is thick in a specific direction along the cross section, and has a cylindrical or bowl-shaped outer shape. As for the upper surface 10a of the molded product 10, the whole area | region 10n is a cylindrical surface, and the lower surface 10b and the side surface 10c of the molded product 10 are flat surfaces. Among these, the upper surface 10a and the lower surface 10b are mirror-shaped molding surfaces as they are molded. As for the side surface 10c, a mirror-like molding surface at the time of molding can be left, but a polished glass-like process can also be performed. In the present embodiment, the entire upper surface 10a is a mirror surface as the predetermined region, but the region including the decorative portion 10d described later of the upper surface 10a may be a mirror surface. For example, the outer edge of the molded product 10 The vicinity need not be mirror-like.

On the upper surface 10a of the molded product 10, a decorative portion 10d is formed as a relief-shaped projection pattern from a local region of the cylindrical surface region 10n. The decorative portion 10d is a three-dimensional structural portion representing characters, patterns, designs, etc., and has a substantially uniform thickness, for example. The thickness or level difference of the decorative portion 10d is, for example, several μm or less, and preferably 1 μm or less. The thickness of the molded product 10 is about several millimeters.

The molded article 10 can be used as, for example, a cover glass or other decorative part or decorative article. The decorative portion 10d formed on the upper surface 10a of the molded product 10 is extremely low, such as several μm or less, but is observed as a pattern that is lightly raised by adjusting the angle of light applied to the molded product 10 and the observation direction. For this reason, it is desirable that the molded product 10 is a colorless or colored transparent member.

The decorative portion 10d provided on the upper surface 10a of the molded product 10 has an edged shape. In other words, the decorative portion 10d has a side surface 11a corresponding to the contour and a flat surface 11b surrounded by the side surface 11a. The side surface 11a rises substantially vertically from the mirror-like peripheral region 10n. If the side surface 11a does not rise substantially perpendicularly from the surrounding area 10n, the step 11a may not be visually recognized due to a small level difference. Further, it can be said that the larger the step amount, the easier the visual recognition of the decorative portion 10d. On the other hand, if the step amount on the side surface 11a is large, press molding becomes difficult. That is, the portion that rises substantially vertically has a strong tendency to mesh with a mold (not shown), and when there is a relatively large difference between the thermal expansion coefficient of the mold and the thermal expansion coefficient of the molded article 10, Stress concentrates on the edge of the side surface 11a and chipping is likely to occur, and release is not easy. Therefore, it becomes difficult to manufacture a good product of the molded product 10 or the yield is lowered. As described above, the setting of the step of the decorative portion 10d has a situation that it is not easy to balance appropriate visibility and ease of manufacture.

Incidentally, the

surfaces

10a and 10b of the molded product 10 are desirably curved surfaces or flat surfaces as designed, but have a slight swell due to the processing accuracy of the mold. Such swell is usually set to be extremely small when the molded article 10 is an optical component or the like, but depending on the application, there is a possibility that the allowable value can be increased to some extent. If the swell is sufficiently larger than the fine step of the molded product 10, it becomes difficult for stress to concentrate on the step during molding, the mold product 10 can be easily released, and the decorative portion 10 d of the molded product 10 is not chipped. It is thought that it becomes difficult to occur. The inventor of the present application pays attention to this point and devised a molding method and a mold that make it difficult to form a chip during manufacture while making the decorative portion 10d of the molded product 10 easy to see.

Hereinafter, an example of a mold and a molding apparatus for manufacturing the molded product 10 shown in FIG. 1A and the like will be specifically described.

As shown in FIG. 2, the mold 40 has an upper mold 41 and a lower mold 42. A transfer surface 41 a is formed on the upper mold 41, and a transfer surface 42 a is also formed on the lower mold 42. The transfer surface 41 a of the upper mold 41 is processed into a mirror surface and has symmetry as a whole, but has a decorative transfer portion 41 d corresponding to the decorative portion 10 d of the molded product 10. The transfer surface 42a of the lower mold 42 is processed into a mirror surface and has symmetry as a whole. Between the upper mold 41 and the lower mold 42, the molten glass GM is filled in a pressed state. The molten glass GM is molded into a flat molded product 10, and a decorative portion 10 d corresponding to the decorative transfer portion 41 d is formed on the molded product 10. A gap is provided between the upper mold 41 and the lower mold 42. This is because the molded article 10 having the same thickness is molded even if the volume of the molten glass GM varies.

With reference to FIGS. 3A to 3C, a description will be given of the undulation of the surface of the molded product 10 that enables the formation of a desired step as the decorative portion 10d of the molded product 10. FIG. FIG. 3A corresponds to FIG. 1B and shows the shape of the upper surface 10a of the molded product 10 in an exaggerated manner. The upper surface 10a is a cylindrical surface and should be an arc 31 as shown by a dotted line, but actually has a shape having an asymmetric undulation U as shown by a solid line. The arc 31 is an approximate R that is a symmetric shape component, and is obtained by fitting the upper surface 10a by, for example, the least square method. FIG. 3B is a diagram showing the shape of the upper surface 10a as a deviation from the arc 31 that is an approximate R. FIG. FIG. 3C is a further enlarged view of FIG. 3B in the vertical direction, in which the undulation U of the upper surface 10a is exaggerated. The decorative portion 10d formed on the upper surface 10a protrudes from the surrounding region 10n so as to overlap the undulation U of the upper surface 10a.

In the example shown in FIG. 3C, the PV (Peak to Valley) value of the undulation component of the upper surface 10 a is larger than the step amount of the decorative portion 10 d on the upper surface 10 a, that is, the decorative uneven step Δ. Since it is difficult for stress to concentrate on the step of the portion 10d, the decorative portion 10d can be prevented from being chipped, the releasability of the molded product 10 can be ensured, and even a fragile material such as glass is formed on the outer periphery of the decorative portion 10d. Chipping is difficult to occur.

With reference to FIGS. 4A and 4B, an appropriate range of the decorative unevenness step Δ formed on the upper surface 10a of the molded product 10 or the transfer surface 41a of the upper mold 41 will be considered. As described with reference to FIG. 3C, if the decorative unevenness Δ is smaller than the PV value of the swell component formed on the upper surface 10a of the molded product 10 or the transfer surface 41a of the upper mold 41, the decorative portion 10d is less likely to be chipped. In addition, it is not easy to perform measurement or the like by distinguishing the decorative uneven step Δ and the swell component on the product. Therefore, the PV value of the surface shape is used instead of the PV value of the swell component. When the PV value of the surface shape is A1, and the PV value of the swell component is A0,
A1 ≦ A0 + Δ, that is, A0 ≧ A1-Δ (1)
It becomes. Here, it is assumed that the PV value A0 of the undulation component is larger than the decorative unevenness step Δ,
A0> Δ (2)
Should be satisfied, and more certainly A1-Δ> Δ (3)
Shall be satisfied. That means
A1 / 2> Δ (4)
Shall be satisfied. That is, the level difference of the decorative portion 10d is smaller than half of the unevenness component taking into account the symmetrical shape component from the upper surface 10a, that is, the PV value A1 of the surface shape. Here, the symmetric shape component means an approximate curve having fine unevenness in a cross section in a predetermined region, and is the same as the approximation R described in FIGS. 3A and 3B. When the above equation (4) is satisfied, the decorative unevenness Δ formed on the upper surface 10a of the molded product 10 is surely smaller than the PV value of the swell component formed on the upper surface 10a of the molded product 10, The mold releasability of the molded product 10 can be ensured at the time of manufacturing the molded product 10, and chipping can be prevented from occurring on the outer periphery of the decorative portion 10d.

Although the above has considered the specific cross section of the molded product 10 or the upper mold 41, it is desirable that the same condition is satisfied in any cross section of the molded product 10, and the arc 31 in FIG. It is strict to think in terms of (or symmetrical shape component surfaces). By treating the deviation or surface accuracy of the upper surface 10a of the molded product 10 or the transfer surface 41a of the upper mold 41 with respect to such a symmetrical shape component, the certainty of the management of the decorative unevenness step Δ and the PV value A1 of the uneven component increases. .

As shown in FIG. 5A, a molding apparatus 100 incorporating the molding die 40 shown in FIG. 2 is an apparatus for pressure molding that directly melts and presses glass as a raw material. In addition to the mold device 60, which is a main member, the molding apparatus 100 includes a control drive device 100a for causing the mold device 60 to perform movement, opening and closing operations, and the like, and a glass droplet forming device 100b ( (See FIG. 5B).

The mold apparatus 60 includes a first mold 61 on the fixed side and a second mold 62 on the movable side. The first molding die 61 has a portion corresponding to the lower die 42 of the molding die 40 shown in FIG. 4 at the tip thereof, and the second molding die 62 corresponds to the upper die 41 of the molding die 40 at the tip thereof. It has a part to do. During molding, the first molding die 61 is maintained in a fixed state, and the second molding die 62 moves so as to face the first molding die 61 so that the molds are closed so that the two

molds

61 and 62 are brought into contact with each other. Done.

The first mold 61 will be described with reference to FIG. 5A. The 1st shaping | molding die 61 is provided with the lower mold | type 42, the support part 61b, and the heater part 61c. Of the first mold 61, the lower mold 42 is cylindrical and has a transfer surface 42a. The heater portion 61c provided at the base of the support portion 61b of the first mold 61 incorporates an electric heater 61h for heating the lower die 42 appropriately.

Next, the second mold 62 will be described. The 2nd shaping | molding die 62 is provided with the upper mold | type 41, the support part 62b, and the heater part 62c. The upper mold 41 of the second mold 62 is cylindrical and has a transfer surface 41a. The heater 62c provided at the base of the support 62b of the second mold 62 incorporates an electric heater 62h for appropriately heating the upper mold 41.

In the second molding die 62 and the first molding die 61, the transfer surface 41a of the second molding die 62 and the transfer surface 42a of the first molding die 61 are arranged coaxially at the time of pressure molding. In addition, an appropriate positional relationship is maintained, such as being separated from each other by a predetermined interval during cooling.

The control drive device 100a controls the supply of electric power to the

electric heaters

61h and 62h and opens and closes the first and second molding dies 61 and 62h for molding the molded product 10 by the mold device 60 or the molding die 40. The entire molding apparatus 100 is controlled. Note that the second mold 62 driven by the control drive device 100a can move in the horizontal AB direction and can move in the vertical CD direction. For example, when performing mold closing by combining both

molds

61 and 62, first, the second mold 62 is moved to a position above the first mold 61 so that the axes CX1 and CX2 of both

molds

61 and 62 coincide with each other. As a result, the upper transfer surface 41a and the lower transfer surface 42a are made to coincide with each other, and the second mold 62 is lowered and pressed against the first mold 61 with a predetermined force.

As shown in FIG. 5B, the glass droplet forming apparatus 100 b includes a raw material supply unit 91. The raw material supply unit 91 is heated by a heater (not shown) so that the glass in the raw material supply unit 91 is in a molten state, and the molten state of the glass dropped from the nozzle 91a is maintained. The raw material supply unit 91 is controlled to move and to drop the molten glass G by the control drive device 100a.

The raw material supply unit 91 stores molten glass G melted in a crucible (not shown) and the like, and the molten glass G is droplet-shaped molten glass G by discharging the molten glass G from the nozzle 91a at a predetermined timing. This is the portion where the droplet GD is dropped.

Hereinafter, an example of a method for manufacturing the molded product 10 will be described. As shown in FIG. 5B, the molten glass droplet GD dropped from the nozzle 91 a of the raw material supply unit 91 is received by the transfer surface 42 a of the lower mold 42. The molten glass droplet GD spreads on the transfer surface 42 a of the lower mold 42 provided in the first mold 61 and is cooled. Then, before the molten glass on the lower mold 42 is completely solidified and at a temperature at which pressure deformation is possible, the upper mold 41 provided in the second mold 62 is relatively placed on the molten glass on the lower mold 42. To be pressed (molding process). At this time, the second molding die 62 is moved to a position above the first molding die 61 so that the axes CX1 and CX2 of both the

molds

61 and 62 coincide with each other, and as a result, the upper transfer surface 41a and the lower transfer surface 42a. And pressed in a state of facing each other. Note that the second mold 62 is heated to a temperature comparable to that of the first mold 61. Thereafter, the temperature of the fused glass between the upper and

lower molds

41 and 42 gradually decreases, whereby the molded product 10 as a decorative panel having the upper and

lower surfaces

10a and 10b is formed. After the molded product 10 is sufficiently cooled, the pressurization of the first molding die 61 and the second molding die 62 is released, and the second molding die 62 is lifted to release the molded product 10 and out of the mold. Take out to (extraction process).

Hereinafter, an example of a manufacturing method of the forming die 40 shown in FIGS. 2 and 4B, in particular, the upper die 41 provided with the decoration transfer portion 41d will be described in detail.

Among the molding dies 40, the upper die 41 is formed into a desired shape by cutting or the like, and has a base surface 41j formed in a mirror shape on the front side. The lower ground 41j of the upper mold 41 has a symmetrical shape macroscopically, and is specifically cut into a cylindrical concave surface. Here, the base surface 41j has a swell as shown in FIG. 4B microscopically. The PV value (vibration width) of such a swell component has a value corresponding to the depth of the decorative transfer portion 41d, and is specifically several μm or more (for example, 8 μm). The undulation of the lower ground 41j can be forcibly provided by machining control, but may be inevitably generated as machining accuracy. The lower ground surface 41j finally becomes a transfer surface 41a having a mirror-like entire surface as a result of finishing processing (mirror processing step). Here, macroscopically means that the surface is uneven when viewed finely, but is specular when the entire predetermined region is observed. In addition, although the lower ground 41j of the upper mold | type 41, ie, a mirror surface, can also be finished by cutting, a mechanical polishing process can also be added finally.

Thereafter, a shallow concave portion having a desired contour is formed on the lower ground 41j of the upper die 41 to form a decorative transfer portion 41d. For example, dry etching (specifically, a gas cluster ion beam) is used to form the decorative transfer portion 41d. Forming a decorative transfer portion 41d having a desired pattern on the transfer surface 41a by forming a mask pattern on the transfer surface 41a after the mirror finishing step (mask forming step) and etching the exposed portion of the mask pattern (Decoration process).

FIG. 6 shows an example of an etching apparatus for forming the decorative transfer portion 41d on the lower ground 41j or the transfer surface 41a of the upper mold 41. The etching apparatus 300 irradiates a gas cluster ion beam (GCIB) for etching the surface of the workpiece WA to be the upper mold 41, and includes an apparatus main body 70, a support apparatus driving unit 81, and a control apparatus. 82.

The apparatus main body 70 is an apparatus that performs polishing by etching using vacuum technology, and includes a source chamber 71a, an ion chamber 71b, and a process chamber 71c. Each

chamber

71a, 71b, 71c is accompanied by an exhaust device 72 including a vacuum pump.

The source chamber 71a is a part that injects gas into vacuum. Gas supplied from the nozzle 73b extending from the gas source 73a is, for example argon gas, oxygen gas, nitrogen gas, SF ₆ gas, other helium gas, a carbon dioxide gas of a compound, mixing two or more gases Is also possible. A skimmer 73c that partitions the source chamber 71a and the ion chamber 71b has an opening, and selectively passes through a gas cluster on the center side of the high-pressure gas ejected from the nozzle 73b to form a beam. That is, the gas cluster beam B1 is emitted from the source chamber 71a.

The ion chamber 71b is a part that turns the gas cluster beam B1 into a gas cluster ion beam B2 for polishing. In the ion chamber 71b, the upstream ionization part 74a has a filament. By causing the thermoelectrons from the filament to collide with the gas cluster beam B1, the gas cluster beam B1 is changed to a charged particle beam. The downstream lens unit 74c converts the charged particle beam that has passed through the acceleration unit 74b into a beam that travels substantially parallel along the irradiation axis AX. As a result, a collimated gas cluster ion beam B2 having a relatively large diameter is emitted from the internal aperture 74f of the ion chamber 71b. The internal aperture 74f also has a shutter function, and can turn on / off the gas cluster ion beam B2 at a desired timing.

Particles constituting the gas cluster ion beam B2 are broken by collision with the workpiece WA by irradiating the workpiece WA, which will be described later, and at that time, the cluster constituent atoms or molecules and the workpiece constituent atoms or molecules And the movement in the horizontal direction becomes significant with respect to the surface of the workpiece WA. Thereby, the protrusions on the surface of the workpiece WA are mainly shaved, and flat ultra-precision polishing at the atomic size becomes possible.

The process chamber 71c is a part that performs a precision polishing process in the order of submicron or nanometer by colliding the gas cluster ion beam B2 against the workpiece WA, and includes a support device 75. The support device 75 includes a stage 75a, supports the workpiece WA on the stage 75a, and adjusts the posture of the workpiece WA with respect to the gas cluster ion beam B2 to a desired state. The workpiece WA corresponds to the state before processing the upper mold 41 of the mold 40, that is, before the decoration transfer portion 41d is formed on the transfer surface 41a, and the remaining portion excluding the portion to be the decoration transfer portion 41d. A mask MA is formed.

The control device 82 comprehensively controls the operation of the device main body 70. That is, the control device 82 operates the device main body 70 as appropriate to etch the surface of the workpiece WA to form a recess having a desired depth. This recess corresponds to a decorative transfer portion 41d to be formed on the transfer surface 41a of the upper mold 41. In addition, the control device 82 directly or indirectly monitors and controls operation states of the gas source 73a, the ionization unit 74a, the acceleration unit 74b, the lens unit 74c, the exhaust device 72, and the like.

During etching, the workpiece WA is fixed on the stage 75a. The workpiece WA is an upper mold 41 on which a base surface 41j is formed, and a mirror-like lower ground 41j to be the transfer surface 41a is locally covered with a mask MA. The mask MA is formed of a resist or the like and has an opening TH at a position corresponding to the decoration transfer portion 41d. When the workpiece cluster WA is irradiated with the gas cluster ion beam B2 for a predetermined time, the base surface 41j is etched at the opening TH, and the decorative transfer portion 41d can be formed as a recess. The depth of the decorative transfer portion 41d is several μm or less, preferably 1 μm or less as described above. As described above, the gas cluster ion beam is suitable for this step because a minute processing amount of 1 μm or less can be targeted with high accuracy by adjusting the irradiation time or the like.

When the etching apparatus 300 shown in FIG. 6 is used, a mirror surface can be formed on the decorative transfer portion 41d. That is, the processing roughness by GCIB can be equal to or higher than the polished surface (mirror surface), so that the bottom surface of the decorative transfer portion 41d is a mirror surface. When the lower ground 41j of the upper mold 41 is ground, smoothness may not be so good. In this case, once the workpiece WA is taken out of the process chamber 71c and the mask MA is removed, the entire transfer surface 41a can be lightly etched with GCIB, and the mirror surface property of the transfer surface 41a can be improved.

According to the molded product or the like of the present embodiment, the stepped amount of the decorative portion 10d is minute when viewed from the entire upper surface 10a that is the molding surface, and the main component of the unevenness of the upper surface 10a is a specular uneven component that covers the entire upper surface 10a. Or it becomes a wave | undulation component. Therefore, the stress at the time of curing shrinkage is not dispersed over the entire upper surface 10a and concentrated on a specific portion, and the glass as the molding material can be released smoothly. Thereby, even if the decorative portion 10d is provided on a transparent material, the molded product 10 is free from white turbidity and chipping.

[Second Embodiment]
Hereinafter, a molded product, a mold, and the like according to the second embodiment of the present invention will be described. The molded product or the like of the second embodiment is a partial modification of the molded product or the like of the first embodiment, and matters not specifically described are the same as those of the first embodiment.

FIG. 7 is a diagram for explaining a mold for molding the molded product of the second embodiment, and is a partial modification of FIG. 4B. The upper mold 41 is provided with a release treatment layer 41q on the lower ground 141j of the base material 41p. In the upper die 41, a decorative transfer portion 41d is formed on the base surface 41j, which is the surface of the release treatment layer 41q, by dry etching or the like as in the first embodiment. That is, the workpiece WA is set on the stage 75a using the etching apparatus 300 shown in FIG. In this case, the workpiece WA corresponds to the state in which the release processing layer 41q is formed on the base material 41p of the upper mold 41, and the mask MA is formed on the remaining portion excluding the portion to be the decoration transfer portion 41d. It has become. The release treatment layer 41q is, for example, any metal of Cr, Ti, and Al or a compound containing them (for example, TiO ₂ , Cr ₂ O ₃ , TiN, TiAlN), or any of Au, Pt, Ir, and Rh. It is a layer formed of such a noble metal or an alloy containing them (for example, Pt—Ir alloy), and is formed by a chemical or physical film forming method (for example, coating or plating) (layer forming step). The layer forming process is performed after the mirror finishing process described in the first embodiment and before the mask forming process.

It is assumed that the thickness t of the release treatment layer 41q is larger than the decorative unevenness step Δ of the decorative transfer portion 41d.
t> Δ (5)
It has become. Thus, by making the value of the thickness t of the release treatment layer 41q larger than the decorative unevenness step Δ, it is possible to prevent the lower ground surface 141j of the base material 41p from being exposed in the decorative transfer portion 41d formed by etching. . Specifically, the thickness t of the release treatment layer 41q is 1 μm or more, preferably several μm or more. The swell component of the release treatment layer 41q is substantially equal to the lower ground surface 141j of the base material 41p. Since the relationship between the decorative unevenness step Δ formed on the release treatment layer 41q and the swell component PV value A0 of the release treatment layer 41q or the base surface 141j is the same as in the first embodiment, a detailed description will be given. Is omitted.

As in the present embodiment, by providing the upper mold 41 with the release treatment layer 41q, the decoration transfer portion 41d can be easily changed. That is, when the mold release layer 41q is removed by wet etching or the like, the lower ground surface 141j of the base material 41p is exposed, and the base surface 141j has a predetermined undulation. When the decorative transfer portion 41d having a different pattern is formed by dry etching or the like, a plurality of types of decorative transfer portions 41d can be easily provided on one base material 41p, and cost reduction can be achieved. In addition, the mold release process layer 41q can also be peeled when this deteriorates. In this case, the life of the upper mold 41 can be made relatively long.

Note that after the decoration transfer portion 41d is formed on the release treatment layer 41q, the entire transfer surface 41a, which is the surface of the release treatment layer 41q, can be lightly etched with GCIB, and the mirror surface property of the transfer surface 41a can be improved. it can.

As mentioned above, although this invention was demonstrated according to embodiment, this invention is not limited to the said embodiment, Various deformation | transformation are possible. For example, the upper surface 10a of the molded product 10 is not limited to a cylindrical surface, but may be a flat surface, a spherical surface, a paraboloid, or the like. In this case, a deviation from an ideal surface such as a plane, a spherical surface, or a paraboloid is considered as a swell component.

In the above description, the case where the decorative transfer portion 41d is formed only on the upper surface 10a of the molded product 10 has been described. However, by processing the lower mold 42 in the same manner as the upper mold 41, the same pattern or another pattern is formed on the lower surface 10b. The decorative transfer portion 41d can be formed.

In the above embodiment, the mask MA for forming the decorative transfer portion 41d on the upper die 41 by etching is not limited to the resist that coats the base surface 41j, but is a metal plate that is arranged away from the upper die 41. May be. In this case, the decoration transfer portion 41d corresponding to the opening pattern formed on the metal plate can be formed.

Moreover, in the said embodiment, although the molded article 10 was formed with glass, you may form with resin.

In the above embodiment, the decorative portion 10d is convex, but may be concave. In this case, the decorative transfer portion 41d of the mold 40 has a convex shape corresponding to the shape of the decorative portion 10d.

Claims

Having a macroscopically shaped molding surface in a predetermined area,
In the predetermined area, having a decorative portion formed in any one of concave and convex in a local area on the molding surface,
The step of the decorative part is a molded product that is smaller than half of the concavo-convex component taking into account the symmetrical shape component from the molding surface.
The molded article according to claim 1, wherein the following conditional expression is satisfied, where Δ is a step of the decorative portion and A1 is a PV value of the surface shape of the molding surface.
A1 / 2> Δ
The molded product according to any one of claims 1 and 2, wherein a step amount of the decorative portion is 1 µm or less.
The molded product according to any one of claims 1 to 3, which is formed of glass.
It has a macroscopic mirror-like transfer surface in a predetermined area,
A decorative transfer portion formed in one of a concave and a convex in a local area on the transfer surface within the predetermined area;
A molding die in which the step amount of the decorative transfer portion is smaller than half of the concavo-convex component taking into account a symmetrical shape component from the transfer surface.
The mold according to claim 5, wherein the following conditional expression is satisfied, where Δ is a step of the decorative transfer portion and A1 is a PV value of the surface shape of the transfer surface.
A1 / 2> Δ
The mold according to any one of claims 5 and 6, wherein the transfer surface has a release treatment layer.
The mold according to claim 7, wherein a thickness of the release treatment layer is larger than a step amount of the decoration transfer portion.
A mirror surface processing step for processing a predetermined region of the transfer surface of the molding die into a mirror surface macroscopically;
A mask forming step of forming a mask pattern corresponding to a decorative transfer portion on the transfer surface in the predetermined region after the mirror surface processing step;
Etching the exposed portion of the mask pattern by dry etching to form the decorative transfer portion; and
The manufacturing method of a shaping | molding die provided with.
The method for manufacturing a mold according to claim 9, wherein a gas cluster ion beam is used in the dry etching.
The manufacturing method of the shaping | molding die as described in any one of Claim 9 and 10 provided with the layer formation process which forms a mold release process layer on the mirror-shaped lower ground after the said mirror-finishing process and before the said mask formation process. Method.
The method for manufacturing a mold according to any one of claims 9 to 11, wherein, in the mirror finishing step, the transfer surface is mirror finished by mechanical polishing.