Molding die and method for manufacturing same

A molding die, comprising:

• a die having a mold plane;
• and
• gloss control granules comprised of:
• 50 to 80 parts by weight of a shape retention fixation base material that is a thermosetting resin;
• 30 to 80 parts by weight of a diffuse reflecting surface formation core material that is a ceramic powder having a shape that is random;
• and
• 5 to 10 parts by weight of a roughness enhancement material that is an inorganic fiber, adhered to the mold plane of the die in a spaced-apart manner,
• wherein the gloss control granules are each independently adhered in a spaced-apart manner to form gloss control projections on the mold plane of the die so that a surface of a molded product molded on the mold plane of the die adhered with the gloss control granules forms a surface having a reflection that is a small specular reflection or a diffuse reflection, and
• wherein the gloss control projections have fine, uneven surfaces with recesses and projections, have strength for enduring molding, are formed with the shape retention fixation base material, have bodies that have different shapes including approximately bell-like bodies, approximately hanging bell-like bodies, approximately discal bodies, approximately dice-like bodies, approximately hemispheroidal bodies, approximately oblate-hemispheroidal bodies, approximately prolate-hemispheroidal bodies cut along planes crossing spherical surfaces having spherical, ellipsoidal, and cocoon shapes, and polyhedrons including truncated cubes, cuboctahedrons, and twisted cubes are formed, and have fine projections protruding from the differently shaped bodies formed of at least one of the roughness enhancement material and the diffuse reflecting surface formation core material.

A molding die, comprising:

• a die having a mold plane;
• and
• gloss control granules comprised of:
• from 50 to 80 parts by weight of a shape retention fixation base material including a thermosetting plastic;
• from 30 to 80 parts by weight of a diffuse reflecting surface formation core material including a ceramic powder having a random shape to increase surface area, to increase surface roughness, and to raise surface recesses and surface projections, and
• from 5 to 10 parts by weight of a roughness enhancement material including an inorganic fiber to form a diffuse reflecting surface by which incident light is diffused in every direction,
• and having have a grain diameter of 1.0 to 100 μm, having a height of 5 to 30 μm;
• wherein the gloss control granules are adhered to the mold plane of the die by spraying using a spray gun in a spaced-apart manner at spacings of from 0.1 to 500 μm, and are each independently adhered in the spaced-apart manner to form gloss control projections by curing the gloss control granules on the mold plane of the die so that a molded product molded on the mold plane of the die adhered with the gloss control granules has a surface having a reflection that is a small specular reflection or a diffuse reflection,
• wherein the gloss control projections formed by the shape retention fixation base material are comprised of the gloss control granules and adhere the gloss control granules to the surface of the mold plane of the die,
• wherein in the gloss control projections have fine, uneven surfaces with recesses and projections, have bodies having different shapes formed of the shape retention fixation base material, and have fine projections protruding from the bodies formed of at least one of the roughness enhancement material and the diffuse reflecting surface formation core material, and the gloss control projections do not melt at least at temperatures of 150° C. and below, and
• wherein the gloss control granules are formed on the mold plane at a coating rate of 40 to 80%.

A molding die, comprising:

• a die having a mold plane;
• and
• gloss control granules comprised of:
• 50 to 80 parts by weight of a shape retention fixation base material including a thermosetting plastic;
• 30 to 80 parts by weight of a diffuse reflecting surface formation core material including a ceramic powder having a random shape to increase a surface area, to increase surface roughness, and to raise the recesses and projections of the surface;
• and
• 5 to 10 parts by weight of a roughness enhancement material including an inorganic fiber to form a diffuse reflecting surface by which incident light is diffused in every direction,
• wherein the gloss control granules are adhered to the mold plane of the die by spraying using a spray gun in a spaced-apart manner at spacings of from 0.1 to 500 μm, have a grain diameter of 1.0 to 100 μm, have a height of 5 to 30 μm, and are each independently adhered in the spaced-apart manner to form gloss control projections by curing the gloss control granules on the mold plane of the die so that a molded product molded on the mold plane of the die adhered with the gloss control granules forms a surface having a reflection that is a small specular reflection or a diffuse reflection;
• wherein the shape retention fixation base material forms the gross control granules constituting the gloss control projections, and is intended to adhere the gloss control granules to the mold plane of the die;
• wherein the gloss control projections have fine, uneven surfaces with recesses and projections, have strength for enduring molding, are formed of the shape retention fixation base material, have bodies that are differently shaped including approximately bell-like bodies, approximately hanging bell-like bodies, approximately discal bodies, and approximately dice-like bodies, approximately hemispheroidal bodies, approximately oblate-hemispheroidal bodies, and approximately prolate-hemispheroidal bodies cut along planes crossing spherical surfaces having spherical, ellipsoidal, and cocoon shapes, and polyhedrons including truncated cubes, cuboctahedrons, and twisted cubes, and have fine projections protruding from the bodies formed of at least one of the roughness enhancement material and the diffuse reflecting surface formation core material, and the gloss control projections do not melt at least at temperatures of 150° C. and below, and
• wherein the gloss control granules are formed on the mold plane at a coating rate of 40 to 80%.

A molding die, comprising:

• a die having a mold plane;
• and
• gloss control granules comprised of:
• 50 to 80 parts by weight of a thermosetting plastic;
• 30 to 80 parts by weight of a ceramic powder;
• and
• 5 to 10 parts by weight of an inorganic fiber,
• adhered to the mold plane of the die in a spaced-apart manner,
• wherein the gloss control granules are adhered so that a molded product molded on the mold plane of the die adhered with the gloss control granules has a surface having a gloss level that at least one of matches and harmonizes with that of another molded product, and
• wherein the gloss control granules have gloss control projections having fine, uneven surfaces with recesses and projections formed on the mold plane at a coating rate of 40 to 80%.

A molding die array, comprising:

• a plurality of dies having respective mold planes for molding molded products composed of different synthetic resin materials and being positioned adjacent to each other;
• and
• gloss control granules provided on at least one mold plate of the plurality of dies and being comprised of:
• 50 to 80 parts by weight of a shape retention fixation base material including a thermosetting plastic,
• 30 to 80 parts by weight of a diffuse reflecting surface formation core material including a ceramic powder having a shape that is random to increase surface area, to increase surface roughness, and to raise recesses and projections of the surface, and
• 5 to 10 parts by weight of a roughness enhancement material including an inorganic fiber to form a diffuse reflecting surface by which incident light is diffused in every direction,
• and having a grain diameter of 1.0 to 100 μm and a height of 5 to 30 μm,
• wherein the gloss control granules are adhered to at least one mold plane by spraying using a spray gun in a spaced-apart manner at spacings of from 0.1 to 500 μm, and are each independently adhered in the spaced-apart manner to form gloss control projections by curing the gloss control granules on the at least one mold plane so that a molded product molded on the mold plane of the die adhered with the gloss control granules has a surface that has a reflection that is a small specular reflection or a diffuse reflection,
• wherein the shape retention fixation base material forms the gross control granules constituting the gloss control projections, and is intended to adhere the gloss control granules to the surface of the mold plane of the die, and
• wherein the gloss control granules are added so that a first molded product molded on the mold plane adhered with the gloss control granules has a surface having a gloss level that at least one of matches and harmonizes with that of a different and other adjacent molded product,
• wherein the gloss control projections have fine, uneven surfaces with recesses and projections, have bodies having different shapes formed with the shape of the retention fixation base material, and have fine projections protruding from the bodies formed of at least one of the roughness enhancement material and the diffuse reflecting surface formation core material, and the gloss control projections do not melt at least at temperatures of 150° C. and below, and
• wherein the gloss control granules are formed on the at least one mold plate at a coating rate of 40 to 80%.

A method for manufacturing a molding die, comprising, in the order recited:

• (a) performing finishing on a molding die having a mold plane for forming a recesses-and-projections-like pattern on the molding die;
• (b) mixing 50 to 80 parts by weight of a shape retention fixation base material that is a thermosetting resin;
• 30 to 80 parts by weight of a diffuse reflecting surface formation core material that is a ceramic powder having a shape that is random;
• 5 to 10 parts by weight of a roughness enhancement material that is an inorganic fiber;
• and 30 to 90 parts by weight of a solvent to provide a composite material mixture;
• (c) spraying the composite material mixture as a fine liquid mist onto the mold plane of the die by compressed air at a coating rate of 40 to 80% to provide a composite material coated mold plane;
• (d) heating the composite material coated mold plane at a temperature of 100 to 150° C. to provide partial adhesion of the composite material thereon and add gloss control granules having fine, uneven surfaces with recesses and projections at a coating rate of 40 to 80% thereon, so that a molded product molded on the mold plane of the die adhered with the gloss control granules has a surface having reflection that is one of a small specular reflection or a diffuse reflection, and the gloss control projections have fine, uneven surfaces with recesses and projections formed at the coating rate of 40 to 80% on the mold plane.

A method for manufacturing a molding die, comprising, in the order recited:

• (a) performing finishing on a molding die having a mold plane for forming a recesses-and-projections-like pattern on the molding die;
• (b) mixing 50 to 80 parts by weight of a shape retention fixation base material that is a thermosetting plastic, 30 to 80 parts by weight of a diffuse reflecting surface formation core material that is a ceramic powder having a shape that is random, 5 to 10 parts by weight of a roughness enhancement material that is an inorganic fiber, and 30 to 90 parts by weight of a solvent to provide a composite material mixture;
• (c) spraying the composite material mixture as a fine liquid mist onto the mold plane of the die by compressed air at a coating rate of 40 to 80% to provide a composite material coated mold plane;
• and
• (d) heating the composite material coated mold plane at a temperature of 100 to 150° C. to solidify the composite material sprayed on the mold plane and add gloss control granules having fine, uneven surfaces with recesses and projections at a coating rate of 40 to 80% on the mold plane,
• wherein a first molded product and a second molded product have respective gloss levels that are compared and are at least one of matched and harmonized by adjusting the added gloss control granules in at least one of the first molded product and the second molded product.