# US 9,434,094 B2 · Molding die and method for manufacturing same

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- Number: US 9,434,094 B2
- Document ID: US9434094B2
- Status: Granted
- Kind: B2
- Application number: 13/816,898
- Filed: 2012-02-21
- Published: 2013-06-06
- Granted: 2016-09-06
- Earliest claimed: 2011-02-28
- Assignees: Tanazawa Hakkosha Co., Ltd.
- Applicants: Kenichi Ueda; Mitsushi Sogabe
- Inventors: Kenichi Ueda; Mitsushi Sogabe
- Web page: https://patentgrep.com/patent/US9434094B2

## CPC

- B29C 33/424: {Moulding surfaces provided with means for marking or patterning (for injection moulding B29C45/372)}
- G02B 1/11: Anti-reflection coatings
- G02B 5/0268: {characterized by the fabrication or manufacturing method}
- B29C 37/0053: {Moulding articles characterised by the shape of the surface, e.g. ribs, high polish (mould construction therefor B29C33/42; surface shaping of articles B29C59/00; by incorporating filler in or near the surface B29C70/64)}
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS

## Abstract

A molding die includes a die having a mold plane; and gloss control granules composed of 50 to 80 pbw of a shape retention fixation base material such as a thermosetting resin; 30 to 80 pbw of a diffuse reflecting surface formation core material such as a ceramic powder; and 5 to 10 pbw of a roughness enhancement material such as an inorganic fiber, adhered to the mold plane in a spaced-apart manner. The gloss control granules are each independently adhered in the 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 die forms a surface having a small specular reflection or a diffuse reflection, and the gloss control projections having fine, uneven surfaces with recesses and projections are formed on the mold plane at a coating rate of 40 to 80%.

## Claims

### Claim 1

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 the 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 having fine, uneven surfaces with recesses and projections are formed on the mold plane at a coating rate of 40 to 80%.

### Claim 2 (depends on 1)

The molding die according to claim 1, wherein the gloss control granule has a grain diameter of 1.0 to 100 μm and a height of 5 to 30 μm.

### Claim 3 (depends on 1)

The molding die according to any of claim 1, wherein the die has a surface region other than that with the gloss control projections having the fine, uneven surfaces with recesses and projections; and a recesses-and-projections-like pattern of the mold plane of the die appears between the respective gloss control granules.

### Claim 4

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.

### Claim 5 (depends on 4)

The molding die according to claim 4, wherein the gloss control granule has a grain diameter of 1.0 to 100 μm and a height of 5 to 30 μm.

### Claim 6 (depends on 4)

The molding die according to claim 4, wherein the die has a surface region other than that with the gloss control projections having the fine, uneven surfaces with recesses and projections, and the mold plane of the die has a recesses-and-projections-like pattern that appears between the respective gloss control granules.

### Claim 7

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%.

### Claim 8 (depends on 7)

The molding die according to claim 7, wherein the gloss control granules are formed by spray-solidifying a composite material in which 50 to 80 parts by weight of a synthetic resin, 30 to 80 parts by weight of a ceramic powder, and 5 to 10 parts by weight of an inorganic fiber are diluted with 30 to 90 parts by weight of a diluting solvent.

### Claim 9

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%.

### Claim 10 (depends on 9)

The molding die according to claim 9, wherein the gloss control granules are formed by spray-solidifying a composite material in which 50 to 80 parts by weight of a synthetic resin, 30 to 80 parts by weight of a ceramic powder, and 5 to 10 parts by weight of an inorganic fiber are diluted with 30 to 90 parts by weight of a diluting solvent.

### Claim 11

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%.

### Claim 12 (depends on 11)

The molding die according to claim 11 wherein the gloss control granules have a grain diameter of 1.0 to 100 μm and a height of 5 to 30 μm.

### Claim 13 (depends on 11)

The molding die according to claim 11, wherein the die has a surface region other than that with the gloss control projections having the fine, uneven surfaces with recesses and projections, and a recesses-and-projections-like pattern of the mold plane of the die appears between the respective gloss control granules.

### Claim 14

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%.

### Claim 15 (depends on 14)

The molding die array according to claim 14, wherein the gloss control granules are formed by spray-solidifying a composite material in which 50 to 80 parts by weight of a synthetic resin, 30 to 80 parts by weight of a ceramic powder, and 5 to 10 parts by weight of an inorganic fiber are diluted with 30 to 90 parts by weight of a diluting solvent.

### Claim 16

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.

### Claim 17 (depends on 16)

The method for manufacturing a molding die according to claim 16, wherein the gloss control granules have a grain diameter of 1.0 to 100 μm and a height of 5 to 30 μm.

### Claim 18 (depends on 16)

The method for manufacturing a molding die according to claim 16, wherein the die has a surface region other than that with the gloss control projections having the fine, uneven surfaces with recesses and projections, and the mold plane of the die has a recesses-and-projections-like pattern that appears between the respective gloss control granules.

### Claim 19

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.

### Claim 20 (depends on 19)

The method for manufacturing a molding die according to claim 19, wherein the gloss control granule has a grain diameter of 1.0 to 100 μm and a height of 5 to 30 μm.