JP7695337B2 - Precision decorated resin molded product, mold, mold manufacturing method and method for manufacturing precision decorated resin molded product - Google Patents

Description

The present invention relates to a precision-decorated resin molded product, a mold, a method for manufacturing a mold, and a method for manufacturing a precision-decorated resin molded product, and in particular to a product having both a plurality of machined areas and a plurality of non-machined areas and a method for manufacturing the same.

In recent years, advances in CAD/CAM technology have significantly improved the design precision of molds, making finer processing possible. For example, Patent Document 1 proposes a method for uniformly forming regular patterns on the processed surface of metal.

Furthermore, Patent Document 2 proposes a design method in which the entire machining surface is divided into the same regular polygon patch or a combination of regular polygon patches of several different shapes, and a spiral tool path is set in one stroke from one vertex within the regular polygon patch, parallel to the side, with a constant crossfeed amount.

Patent No. 4752061 Patent No. 5028611

However, when using actual CAD/CAM technology to form a molded product using precision decorative resin molding, if processing is performed using a specific pattern, the result is often a monotonous series of patterns. On the other hand, since more precise design is possible, if a precise figure is drawn, the design time may become enormous.
As a result of extensive research, the applicants have discovered that in order to perform more delicate and precise processing on the surface of a mold, it is necessary to incorporate not just one type of cutting metal processing method, but multiple types, and even to incorporate non-cutting metal processing methods, thereby making it possible to achieve precision decorative resin molding that has not been possible before.

The object of the present invention is to provide a precision-decorated resin molded product, a mold, a method for manufacturing a mold, and a method for manufacturing a precision-decorated resin molded product, in particular one that has both a plurality of machined areas and a plurality of non-machined areas.

The precision-decorated resin molded product of the present invention is a precision-decorated resin molded product formed by injection molding into a mold, and its surface has at least two or more regions, which are at least two or more of a non-cut resin surface formed by a mold surface processed by a non-cutting processing technique, a first cut resin surface formed by a mold surface formed by a first cutting processing technique, and a second cut resin surface formed by a mold surface formed by a second cutting processing technique which has different conditions from the first cut resin surface.

The non-cutting processing techniques include mirror polishing, embossing, photoetching, blasting, laser processing or a combination thereof.

The first cutting technique or the second cutting technique uses the same cutting tool, but the pitch of adjacent tool paths when the cutting tool moves is different.

The first cutting processing technique or the second cutting processing technique has a different cutting direction of a cutting tool for the first cutting processing technique from the cutting direction of a cutting tool for the second cutting processing technique.

The first cutting processing technique or the second cutting processing technique is characterized in that the cutting tool of the first cutting processing technique engraves in a straight line, and the cutting tool of the second cutting processing technique engraves in a curved line.

In the first cutting processing technique or the second cutting processing technique, the cutting tool of the first cutting processing technique engraves in a curved shape, and the cutting tool of the second cutting processing technique is also curved and engraves on a curve with a different curvature, etc.

In either the first cutting technique or the second cutting technique, the cutting direction is parallel to the contour lines.

Either the first cutting technique or the second cutting technique has a cutting direction that is non-parallel to the contour lines.

The precision-decorated resin molded product of the present invention is a precision-decorated resin molded product formed by injection molding in a metal mold, and its surface has at least two or more regions. The multiple regions are formed by forming a regular polygon in a spiral shape with a continuous line using a machining tool, which moves a certain distance and then changes direction at the same angle.

The precision-decorated resin molded product of the present invention is a precision-decorated resin molded product formed by injection molding into a mold, in which the surface of a naturally occurring natural product is measured in advance as three-dimensional coordinates for the entire surface over any area, a reference plane for that surface is determined in advance, and the three-dimensional coordinates are converted into emphasized three-dimensional coordinates by multiplying only the numerical values in the height direction from the reference plane by a specific coefficient value, and the product is formed using a mold that forms a surface region using the emphasized three-dimensional coordinates to form multiple regions.

Letters, shapes or a combination of both are formed on different resin surfaces.

The interval between tool movements when cutting each area of the mold is the interval that results in a white gloss after molding.

The interval between tool movements when cutting each area of the mold is the interval that results in an iridescent luster after molding.

The regular polygon is a hexagon.

Stone is a natural material.

The mold for forming precision-decorated resin molded products according to the present invention is a mold for forming precision-decorated resin molded products formed by injection molding into a mold, and its surface has at least two or more regions, which are at least two or more of a non-cut resin surface of the mold processed by a non-cutting processing technique, a first cut resin surface of the mold surface formed by a first cutting processing technique, and a second cut resin surface of the mold surface formed by a second cutting processing technique which has different conditions from the first cut resin surface.

The precision decorative resin molding method of the present invention is a precision decorative resin molding method in which a resin is injection molded into a mold, and the surface of the resin has at least two or more regions, which are at least two or more of a non-cut resin surface formed by a mold surface processed by a non-cutting processing technique, a first cut resin surface formed by a mold surface formed by a first cutting processing technique, and a second cut resin surface formed by a mold surface formed by a second cutting processing technique that has different conditions from the first cut resin surface.

The present invention relates to a method for manufacturing a mold for forming a precision decorated resin molded product, the method comprising the steps of:
The surface has at least two or more regions, which include at least two or more regions of a non-cut resin surface of the mold processed by a non-cutting processing technique, a first cut resin surface of the mold surface formed by a first cutting processing technique, and a second cut resin surface of the mold surface formed by a second cutting processing technique which has different conditions from the first cut resin surface.

The precision-decorated resin molded product, mold, mold manufacturing method, and precision-decorated resin molded product of the present invention, in particular by combining multiple cutting areas and non-cutting areas, make it possible to provide unprecedented precision-decorated resin molding.

1 is a configuration diagram of an automobile part formed by a first embodiment of a precision decorated resin molded product according to the present invention; 1 is a conceptual diagram of a machining center for manufacturing a mold for forming a first embodiment of a precision-decorated resin molded product according to the present invention. 1 is a conceptual diagram of a mold for forming a first embodiment of a precision-decorated resin molded product according to the present invention. 1 is a conceptual diagram of a first embodiment of a precision-decorated resin molded product according to the present invention. FIG. 2 is a conceptual diagram of a second embodiment of a precision-decorated resin molded product according to the present invention. FIG. 11 is a conceptual diagram of a third embodiment of a precision-decorated resin molded product according to the present invention. FIG. 11 is a conceptual diagram of a fourth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 13 is a conceptual diagram of a fifth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 13 is a conceptual diagram of a sixth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 13 is a conceptual diagram of a seventh embodiment of a precision-decorated resin molded product according to the present invention. FIG. 13 is a conceptual diagram of an eighth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 13 is a conceptual diagram of a ninth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 11 is a conceptual diagram of a tenth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 15 is a conceptual diagram of an eleventh embodiment of a precision-decorated resin molded product according to the present invention. FIG. 23 is a conceptual diagram of a twelfth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 23 is a conceptual diagram of a thirteenth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 23 is a conceptual diagram of a fourteenth embodiment of the precision decorated resin molded product according to the present invention. FIG. 23 is a diagram showing the configuration of a fifteenth embodiment of the precision decorated resin molded product according to the present invention. FIG. 21 is an enlarged configuration diagram of a sixteenth embodiment of the precision decorated resin molded product according to the present invention. FIG. 21 is an enlarged configuration diagram of a sixteenth embodiment of the precision decorated resin molded product according to the present invention. FIG. 21 is an enlarged configuration diagram of a sixteenth embodiment of the precision decorated resin molded product according to the present invention. FIG. 21 is an enlarged configuration diagram of a sixteenth embodiment of the precision decorated resin molded product according to the present invention. 16 is a natural sample of a precision-decorated resin molded product according to the present invention. 16 is a natural sample of a precision-decorated resin molded product according to the present invention. 16 is a natural sample of a precision-decorated resin molded product according to the present invention. 16 is a natural sample of a precision-decorated resin molded product according to the present invention. 16 is a natural sample of a precision-decorated resin molded product according to the present invention. 1 is a configuration diagram of a precision-decorated resin molded product according to a first embodiment of the present invention; 1 is an enlarged configuration diagram of a precision-decorated resin molded product according to a first embodiment of the present invention; FIG. 11 is a configuration diagram of a precision-decorated resin molded product according to a second embodiment of the present invention. FIG. 11 is an enlarged configuration diagram of a precision-decorated resin molded product according to a second embodiment of the present invention. FIG. 11 is a configuration diagram of a precision decorated resin molded product according to a third embodiment of the present invention. FIG. 11 is an enlarged configuration diagram of a precision-decorated resin molded product according to a third embodiment of the present invention. FIG. 11 is a diagram showing the configuration of a precision-decorated resin molded product according to a fourth embodiment of the present invention. FIG. 11 is an enlarged configuration diagram of a precision-decorated resin molded product according to a fourth embodiment of the present invention. FIG. 11 is a diagram showing the configuration of a precision-decorated resin molded product according to a fifth embodiment of the present invention. FIG. 11 is an enlarged configuration diagram of a precision-decorated resin molded product according to a fifth embodiment of the present invention. FIG. 13 is a diagram showing the configuration of a precision-decorated resin molded product according to a sixth embodiment of the present invention. FIG. 13 is an enlarged configuration diagram of a precision-decorated resin molded product according to a sixth embodiment of the present invention. FIG. 13 is a diagram showing the configuration of a precision-decorated resin molded product according to a seventh embodiment of the present invention. FIG. 13 is an enlarged configuration diagram of a precision-decorated resin molded product according to a seventh embodiment of the present invention. FIG. 13 is a diagram showing the configuration of an eighth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 13 is an enlarged configuration diagram of a precision-decorated resin molded product according to an eighth embodiment of the present invention. 13 is a block diagram of an eighth embodiment of a precision-decorated resin molded product according to the present invention. FIG. 13 is a diagram showing the configuration of a precision-decorated resin molded product according to a ninth embodiment of the present invention. FIG. 13 is an enlarged configuration diagram of a precision-decorated resin molded product according to a ninth embodiment of the present invention. 13 is a block diagram of a precision-decorated resin molded product according to a ninth embodiment of the present invention. FIG. 17 is a diagram showing the configuration of a precision-decorated resin molded product according to a tenth embodiment of the present invention. FIG. 15 is an enlarged configuration diagram of a precision-decorated resin molded product according to a tenth embodiment of the present invention. 13 is a 3D scanned image of Example 10 of a precision-decorated resin molded product according to the present invention. FIG. 15 is a cross-sectional view of a precision-decorated resin molded product according to a tenth embodiment of the present invention. FIG. 15 is an enlarged cross-sectional view of a precision-decorated resin molded product according to a tenth embodiment of the present invention. 13 is a block diagram of a precision-decorated resin molded product according to a tenth embodiment of the present invention. FIG. 15 is a diagram showing the configuration of an eleventh embodiment of a precision-decorated resin molded product according to the present invention.

Next, an embodiment of the present invention will be described in detail with reference to the drawings. In all the drawings described below, the same components are given the same reference numerals and the description will be omitted as appropriate.

First Embodiment
The first embodiment is a configuration of a precision decorated resin molded product, and examples of the precision decorated resin molded product include an exterior cover for an audio product as a housing for an electric product, a bumper or door mirror as an exterior part of an automobile, or a dashboard 4, an instrument panel 6, a center cluster 8, a steering wheel 10, a meter 12, a shift lever 13, etc. as an interior part 2 of an automobile, as shown in Fig. 1. All or a part of these can be composed of the precision decorated resin molded product.

Resin molded products are formed by injecting and filling a mold having a cavity with a precisely decorated resin part with resin. Figure 2 is an explanatory diagram showing a machining center 22 that processes the mold according to the embodiment. The machining center 22 has a machine tool body 24 and a control device 26.

The machine tool body 24 performs cutting on the surface of the workpiece 28 to be machined, forming a cavity that is a component of a mold. The machine tool body 24 has a spindle 32 that rotatably supports the cutting tool 30, and a well-known means for moving the workpiece 28 in three dimensions.

The cutting tool 30 is preferably an end mill, particularly a ball end mill. The spindle 32 rotates the cutting tool 30 around the Z axis, and the well-known means moves the workpiece 28 freely in the X, Y, and Z directions.

The control device 26 is composed of an electronic computer in which a central integrated circuit, an internal memory device, an external memory device, an external interface, and a cutting tool interface are connected by internal wiring, and controls the machine tool body 24 according to NC data. The NC data includes a tool path, which is the movement path of the cutting tool 30 defined by the amount of movement in the X direction, the amount of movement in the Y direction, the amount of movement in the Z direction, the rotation speed of the main shaft, the feed rate in the X direction, the feed rate in the Y direction, and the movement rate in the Z direction. The control device 26 moves the workpiece 28 according to the NC data, so that a cavity and a precisely decorated resin pattern can be cut into the surface of the workpiece 28.

Here, the process of creating NC data is an important process of the present invention. The tool path is designed using a CAD/CAM system, and the structure of the precision decorative resin pattern is designed using CAD. As the tool path, a tool path such as a ball end mill is formed, so that the precision decorative resin pattern can be reproduced on the surface of the mold. Here, the diameter of the ball end mill is preferably R0.2 to R2, and the tool path interval is characterized by being 25 μm to 500 μm. Furthermore, the shape height from the highest point to the lowest point is 0.05 mm to 0.2 mm, which allows for precision decorative resin processing.

Figure 3 is a perspective view showing the entire mold 40 according to the present invention. A forming portion formed by non-cutting or cutting techniques is added to the inner surface of the mold 40, which is inside the mold 40 and not shown. The forming portion is cut into a shape that is the inverse of the mold shape so that the mold shape is formed on the surface of the resin molded product.

Next, we will explain the manufacturing method of the mold 50 and the manufacturing method of the molded product in the first embodiment.

First, it is decided what design will be formed on which part of the resin molded product. Once the design of the resin molded product has been finalized, the mold to realize the design of the resin molded product is designed. In designing the mold, either cutting or non-cutting processing techniques may be used depending on the surface state of the molded product when completed. Furthermore, when there are multiple surfaces on the surface of a single resin molded product, the surface of the mold will be processed using both cutting and non-cutting processing techniques. Here, in the first embodiment, as shown in Figure 4A, the mold 50 is composed of a mirror surface portion 52 that uses non-cutting processing technology, and a cutting portion 54 that uses cutting processing technology.

The mirror surface portion 52 is polished to a mirror finish using a grinding stone, polishing paper, and diamond paste.

The cutting section 54 uses CAD data, which is the drawing data of the molded product that has been input in advance, to generate a tool path 56 using a CAM system for generating tool paths. The tool path 56 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 56, cusps 58 are formed on both ends of the tool path parallel to the tool path.

Meanwhile, the cut mold 50 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 50 and cooled and solidified to form a resin molded product. As a result, a flat surface corresponding to the mirror surface 52 is formed on one side, and a shape is formed in which the portion corresponding to the cut portion 54 is recessed in the portion corresponding to the cusp 58. With this embodiment, a molded product can be obtained that has a flat portion and a portion decorated by cutting.

Second Embodiment
A method for manufacturing a mold 60 and a molded product in the second embodiment will be described below. In particular, differences from the first embodiment will be described. As shown in FIG. 4B, the second embodiment is composed of a mold 60 having an embossed portion 62 formed using a non-cutting technique and a cut portion 64 formed using a cutting technique.

The embossed portion 62 is formed with a wrinkle pattern 63. Specifically, the wrinkle pattern 63 is transferred to the embossed portion 62 of the mold 60 using acid-resistant ink.

Furthermore, when etching is performed, areas not covered by the acid-resistant ink are corroded to remove metal, creating depressions.

The remaining part is then newly transferred using acid-resistant ink.

If etching is then performed, the areas not covered with ink will have depressions, but the first etched area will have an even larger depression.

A third transfer is then made on top of this using acid-resistant ink.

A third etching is then performed from above, creating a more complex and deeper depression than the second etching. The above processing creates the embossed portion 62. By using this mold 60, a molded product having the shape defined by the embossed portion 62 is formed.

The cutting portion 64 is formed in the same manner as in the first embodiment.

Meanwhile, the machined mold 60 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 60 and cooled and solidified to form a resin molded product. As a result, an embossed surface corresponding to the embossed portion 62 is formed on one side, and a shape is formed in which the portion corresponding to the cut portion 64 corresponds to the cusp 68 and has a recess.

With this embodiment, a molded product can be obtained that has a portion decorated by embossing and a portion decorated by cutting.

Third Embodiment
A method for manufacturing a mold 70 and a molded product in the third embodiment will be described below. In particular, differences from the first embodiment will be described. As shown in FIG. 4C, the third embodiment is composed of a mold 70 having a photo-etched section 72 that uses a non-cutting technique and a cut section 74 that uses a cutting technique.

In the photo-etched portion 72, an etched recess pattern 73 is formed. Specifically, a pattern film is created on which the etching pattern to be processed in the photo-etched portion 72 of the mold 70 is drawn, the photo-etched portion 72 is degreased and cleaned, photoresist is applied to the photo-etched portion 72, the pattern film is stretched from above and exposed to a semiconductor laser or the like, then a development process is performed, and an etching process is performed to remove the shape according to the pattern. The masking is then removed to form the photo-etched portion 72.

The cutting portion 74 is formed in the same manner as in the first embodiment.

Meanwhile, the machined mold 70 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 70 and cooled and solidified to form a resin molded product. As a result, a photoetched surface corresponding to the photoetched portion 72 is formed on one side, and the portion corresponding to the cut portion 74 is formed with a recess in the portion corresponding to the cusp 78.

With this embodiment, a molded product can be obtained that has a portion decorated by photoetching and a portion decorated by cutting.

(Fourth embodiment)
A method for manufacturing a mold 80 and a molded product in the fourth embodiment will be described below. In particular, differences from the first embodiment will be described. As shown in FIG. 4D, the fourth embodiment is composed of a blasted section 82 using a non-cutting technique in the mold 80 and a cut section 84 using a cutting technique.

The blasted portion 82 is formed with a blasted recess pattern 83. Specifically, granular abrasives of an appropriate size to be processed into the blasted portion 82 of the mold 80 are struck at high speed against the metal surface to remove surface scale (e.g., iron oxide), rust, and other foreign matter, or to condition the base material of the metal surface. Silica sand, silicon carbide, alumina, etc. are mainly used as abrasives. The blasted portion 82 is formed by these abrasives.

The cutting portion 84 is formed in the same manner as in the first embodiment.

Meanwhile, the machined mold 80 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 80 and cooled and solidified to form a resin molded product. As a result, a blasted surface corresponding to the blasted portion 82 is formed on one side, and a shape is formed in which the portion corresponding to the cut portion 84 corresponds to the cusp 88 and has a recess.

With this embodiment, a molded product can be obtained that has a portion decorated by blasting and a portion decorated by cutting.

Fifth Embodiment
A method for manufacturing a mold 90 and a molded product in the fifth embodiment will be described below. In particular, differences from the first embodiment will be described. As shown in FIG. 4E, the fifth embodiment is composed of a mold 90 having a laser processed portion 92 that uses a non-cutting technique and a cutting portion 94 that uses a cutting technique.

A laser recess pattern 93 is formed in the laser processed portion 92. Specifically, an ultrashort pulse laser is irradiated to the laser processed portion 92 of the mold 90 based on design data while being moved, to process the mold surface. In this case, by using a picosecond or femtosecond laser or a laser requiring higher precision rather than a continuous laser or nanosecond laser, the generation of burrs and thermal damage can be prevented.

The cutting portion 94 is formed in the same manner as in the first embodiment.

Meanwhile, the machined mold 90 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 90 and cooled and solidified to form a resin molded product. As a result, a laser-machined surface corresponding to the laser-machined portion 92 is formed on one side, and a shape is formed in which the portion corresponding to the cut portion 94 corresponds to the cusp 98 and has a recess.

With this embodiment, a molded product can be obtained that has parts that are decorated by laser processing and parts that are decorated by cutting processing.

Sixth Embodiment
A method for manufacturing a mold 100 and a molded product in the sixth embodiment will be described below. In particular, differences from the first embodiment will be described. As shown in FIG. 4F, the sixth embodiment is composed of a mold 100 having an electric discharge machining section 102 that uses a non-cutting machining technique and a cutting section 104 that uses a cutting technique.

The electric discharge machining portion 102 forms an electric discharge machining pattern 103. Specifically, an electric discharge die engraving machine or a wire electric discharge machine is moved to the electric discharge machining portion 102 of the die 100 based on design data to machine the die surface. At this time, if a wire electric discharge machine is used, it can be controlled by NC data.

These processes form the electric discharge machined portion 102.

The cutting portion 104 is formed in the same manner as in the first embodiment.

Meanwhile, the machined mold 100 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 100 and cooled and solidified to form a resin molded product. As a result, an electric discharge machined surface corresponding to the electric discharge machined portion 102 is formed on one side, and a shape is formed in which the portion corresponding to the cutting portion 104 corresponds to the cusp 108 and has a recess.

This embodiment makes it possible to obtain a molded product having a portion decorated by electrical discharge machining and a portion decorated by cutting machining.

Seventh Embodiment
Next, a method for manufacturing the mold 110 and the molded product in a seventh embodiment of the precision decorated resin molded product according to the present invention will be described. The seventh embodiment is different from the sixth embodiment only in the processing method of the cut portion 114.
The cutting unit 114 generates a tool path 116 using a CAM system from the CAD data (FIG. 4G). The tool path 116 is set so that the ball end mill moves in the designed direction. Here, in the first to sixth embodiments, adjacent tool paths are designed so that the tool moves in the opposite direction. By reversing the moving direction, the tool return process can also be used as processing time, which has the effect of shortening the cutting time. On the other hand, in the seventh embodiment, all adjacent tool paths cut in the same direction. By processing all cutting directions in the same direction in this way, the cutting marks and the like tend to have the same tendency, so the finish is uniform, the appearance is uniform, and the appearance is not rough, resulting in desirable traces. Therefore, the molded products molded with a mold created by this method also have the effect of having a uniform finish.

Eighth embodiment
Further, a method for manufacturing a mold 120 and a method for manufacturing a molded product in the eighth embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5A, the sixth embodiment is composed of a first pitch cut portion 122 and a second pitch cut portion 124 in the mold 120, both of which are made using a cutting technique.

The first pitch cutting unit 122 generates a tool path 126 from the CAD data using a CAM system. The tool path 126 is set so that the ball end mill moves in a designed direction. When the ball end mill cuts the mold along the tool path 126, cusps 128 are formed on both ends of the tool path parallel to the tool path, separated by a first pitch derived from the cutting width of the ball end mill.

On the other hand, the second pitch cutting unit 124 generates a tool path 130 from the CAD data using a CAM system. The tool path 130 is set so that the ball end mill moves in the direction designed. When the ball end mill cuts the mold along the tool path 130, cusps 132 are formed on both ends parallel to the tool path, separated by a second pitch narrower than the first pitch due to the cutting width of the ball end mill.

Next, the processed mold 120 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 120 and cooled and solidified to form a resin molded product. As a result, a shape is formed in which the portion corresponding to the first pitch cut portion 122 is recessed at the portion corresponding to the cusp 128, and on the other hand, a shape is formed in which the portion corresponding to the second pitch cut portion 124 is recessed at the portion corresponding to the cusp 132.

This embodiment makes it possible to obtain a molded product having decorated portions that are created by cutting with different pitches.

Ninth embodiment
Further, a method for manufacturing a mold 140 and a method for manufacturing a molded product in the ninth embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5B, the ninth embodiment is composed of a first direction cutting part 142 and a second direction cutting part 144 in the mold 140, both of which use cutting technology.

The first direction cutting unit 142 generates a tool path 146 from CAD data using a CAM system. The tool path 146 is set so that the ball end mill moves in a designed direction. When the ball end mill cuts the mold along the tool path 146, cusps 148 are formed on both ends of the tool path parallel to the tool path, separated by a first pitch derived from the cutting width of the ball end mill.

On the other hand, the second direction cutting unit 144 uses a CAM system to generate a tool path 150 whose cutting direction is 90 degrees different from that of the tool path 146 from the CAD data. The tool path 150 is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path 150, cusps 152 are formed at both ends parallel to the tool path, separated by a first pitch due to the cutting width of the ball end mill.

Next, the processed mold 140 is incorporated into an injection molding machine, and a molding resin is injected into the cavity formed by the mold 140 and cooled and solidified to form a resin molded product. As a result, a shape is formed in which the portion corresponding to the first direction cutting portion 142 is recessed at the portion corresponding to the cusp 148, and on the other hand, a shape is formed in which the portion corresponding to the second direction cutting portion 144 is recessed at the portion corresponding to the cusp 152.
According to this embodiment, a molded product having portions decorated by cutting in different directions can be obtained.

Tenth Embodiment
A method for manufacturing a mold 160 and a molded product in the tenth embodiment will be described below. In particular, differences from the first embodiment will be described. As shown in FIG. 5C, the tenth embodiment is composed of a mold 160 having a linear cut portion 162 and a curved cut portion 164, both of which are made using a cutting technique.

As in the first and second embodiments, the linear cutting section 162 generates a tool path 166 from CAD data using a CAM system. The tool path 166 is set so that the ball end mill moves in a designed direction. When the ball end mill cuts the mold along the tool path 166, cusps 168 are formed on both ends of the tool path parallel to the tool path, separated by a first pitch derived from the cutting width of the ball end mill.

On the other hand, the curve cutting unit 164 generates a curved tool path 170 from the CAD data using a CAM system. The tool path 170 is set so that the ball end mill moves in a curved manner in the direction designed. When the ball end mill cuts the mold along the tool path 170, cusps 172 are formed on both ends of the tool path, parallel to the tool path and separated by a first pitch due to the cutting width of the ball end mill.

Next, the processed mold 160 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 160 and cooled and solidified to form a resin molded product. As a result, a shape is formed in which the portion corresponding to the straight cut portion 162 is recessed at the portion corresponding to the cusp 168, and on the other hand, a shape is formed in which the portion corresponding to the curved cut portion 164 is recessed at the portion corresponding to the cusp 172.

This embodiment makes it possible to obtain a molded product having a decorated portion through curved cutting and straight cutting.

Eleventh Embodiment
Furthermore, a method for manufacturing a mold 180 and a method for manufacturing a molded product in the eleventh embodiment will be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5D, the eleventh embodiment is composed of a mold 180 having a curved cut portion 182 with a first curvature, both of which are made using a cutting technique, and a curved cut portion 184 with a second curvature, both of which are made using a cutting technique.

The first curvature curve cutting unit 182 generates a tool path 186 from CAD data using a CAM system, as in the ninth embodiment. The tool path 186 is set so that the ball end mill moves in a designed direction. When the ball end mill cuts the mold along the tool path 186, a first curvature cusp 188 is formed on both ends of the tool path parallel to the tool path, separated by a first pitch derived from the cutting width of the ball end mill.

On the other hand, the second curvature curve cutting section 184 generates a tool path 190 of the second curvature curve from CAD data using a CAM system. The tool path 190 is set so that the ball end mill moves in a curved shape in the direction designed. When the ball end mill cuts the mold along the tool path 190, cusps 192 are formed on both ends of the tool path 190, separated by a first pitch due to the cutting width of the ball end mill, on the second curvature curve and parallel to the tool path.

Next, the processed mold 180 is incorporated into an injection molding machine, and molding resin is injected into the cavity formed by the mold 180 and cooled and solidified to form a resin molded product. As a result, a shape is formed in which the portion corresponding to the first curvature curved cut portion 182 is recessed in the portion corresponding to the first curvature cusp 188, and on the other hand, a shape is formed in which the portion corresponding to the second curvature curved cut portion 184 is recessed in the portion corresponding to the second curvature cusp 192.

With this embodiment, a molded product having a portion decorated by first curvature curve cutting processing and second curvature cutting processing can be obtained.

Twelfth Embodiment
A method for manufacturing a mold 200 and a molded product in the twelfth embodiment will now be described. In particular, differences from the first embodiment will be described. As shown in FIG. 5E, the mold 200 in the twelfth embodiment is composed of a linear cut portion 202 and a contour-parallel cut portion 204, both of which are made using a cutting technique.

As in the first and second embodiments, the linear cutting section 202 generates a tool path 206 from CAD data using a CAM system. The tool path 206 is set so that the ball end mill moves in a designed direction. When the ball end mill cuts the mold along the tool path 206, cusps 208 are formed on both ends of the tool path parallel to the tool path, separated by a first pitch derived from the cutting width of the ball end mill.

On the other hand, the contour parallel cutting unit 204 generates tool paths 216, 218 parallel to the contour lines 210, 212, 214 using a CAM system from CAD data. The tool paths 216, 218 are set so that the ball end mill moves parallel to the contour lines in the direction designed by the ball end mill. When the ball end mill cuts the mold along the tool paths 216, 218, cusps that are also the contour lines 210, 212, 214 are formed at both ends parallel to the tool path, separated by a first pitch due to the cutting width of the ball end mill.

The machined mold 200 is then installed in an injection molding machine, and molding resin is injected into the cavity formed by the mold 200 and cooled and solidified to form a resin molded product. As a result, a shape is formed in which the portion corresponding to the cusp 208 is recessed in the portion corresponding to the linear cut portion 202, and a shape is formed in which the portion corresponding to the contour-parallel cut portion 204 is recessed in the portion parallel to the contour.

With this embodiment, a molded product having a decorated portion can be obtained by contour parallel cutting and straight line cutting.

Thirteenth Embodiment
Further, a method for manufacturing a mold 220 and a method for manufacturing a molded product in the thirteenth embodiment will be described. In particular, differences from the twelfth embodiment will be described. As shown in Fig. 5F, the thirteenth embodiment is composed of a straight cut portion 222 in the mold 220, both of which are made using a cutting technique, and a non-parallel contour cut portion 224, both of which are made using a cutting technique. The straight cut portion 222 is the same as in the twelfth embodiment, and will not be described here.

Here, the contour non-parallel cutting unit 224 generates tool paths 236, 238, 240, 242, 244, 246, 248, 250 that are non-parallel to the contour lines 230, 232, 234 using a CAM system from CAD data. The tool paths 236, 240, 244, 248 are cut in a direction perpendicular to the contour lines from the center of the contour lines toward the outer edge, and the tool paths 238, 242, 246, 250 are cut from the outer edge toward the center of the contour lines. When the ball end mill cuts the mold along the tool paths 236, 240, 244, 248, cusps are formed at both ends perpendicular to the contour lines and the tool paths at a first pitch due to the cutting width of the ball end mill.

The machined mold 220 is then installed in an injection molding machine, and molding resin is injected into the cavity formed by the mold 220 and cooled and solidified to form a resin molded product. As a result, a shape is formed in which the portion corresponding to the straight cut portion 222 on one side is recessed in the portion corresponding to the cusp 228, and on the other hand, a recess is formed in the portion corresponding to the non-parallel cut portion 224 on the other side, perpendicular to the contour lines.

This embodiment makes it possible to obtain a molded product having a decorated portion using non-parallel contour cutting and straight line cutting.

(Fourteenth embodiment)
Further, a method for manufacturing a mold 260 and a method for manufacturing a molded product in the fourteenth embodiment will be described. In particular, differences from the first embodiment will be described. In the fourteenth embodiment, as shown in FIG. 5G, the mold 260 is provided with concentric circular boundary lines 262, 264, 266, 268, 270, 272, 274, 276 and radial boundary lines 261, 263, 265 in the axial direction for a circular pattern, and adjacent regions are machined by different machining methods. As one method, the cutting direction is changed by 90 degrees in adjacent regions to machine the entire circumference.

The first direction cutting unit 278 generates a first tool path in the circumferential direction from CAD data using a CAM system. The first tool path is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the tool path, cusps are formed at both ends parallel to the tool path, separated by a first pitch derived from the cutting width of the ball end mill.

Meanwhile, the second direction cutting unit 280 uses a CAM system to generate a second tool path from the CAD data, whose cutting direction differs by 90 degrees from the first tool path. The second tool path is set so that the ball end mill moves in the designed direction. When the ball end mill cuts the mold along the second tool path, cusps are formed at both ends parallel to the tool path, separated by the first pitch due to the cutting width of the ball end mill. This process is carried out across the front of the decorative pattern.

The machined mold 260 is then installed in an injection molding machine, and molding resin is injected into the cavity formed by the mold 260 and cooled and solidified to form a resin molded product. As a result, a shape is formed in which the portion corresponding to the cusp is recessed at the portion corresponding to the first direction cut portion, and a shape is formed in which the portion corresponding to the cusp is recessed at the portion corresponding to the second direction cut portion.

This embodiment makes it possible to obtain a molded product having decorated portions that are cut in different directions.

Fifteenth Embodiment
Further, a method for manufacturing a mold 290 and a method for manufacturing a molded product in the fifteenth embodiment will be described. In particular, differences from the first embodiment will be described. In the fifteenth embodiment, as shown in FIG. 6, in the mold 290, a cutting tool is machined adjacent to the mold 290 in a specific direction multiple times, thereby forming cusps 296 parallel to the tool paths 292 and 294. Here, if the interval l of the cusps 296 is set to 100 nm to 600 nm, the adjacent cut marks made by the cutting tool will cause reflection, and adjacent reflected lights will interfere with each other to cause rainbow reflection. This can occur in both the mold and the molded product. In addition, if the surface roughness, which is the height of the cusps, is set to 0.00 to 0.20 μm, the light will not be rainbow-colored but will be mirror-reflected light, and if the surface roughness is 0.20 to 0.40 μm, the molding surface formed by the cusps will be rainbow-colored, and if the surface roughness is 0.40 μm or more, the light will have a white luster.

Sixteenth Embodiment
Next, in the sixteenth embodiment, a method of drawing a natural object on the surface of a mold for decoration will be described. Here, ripples on the surface of a shallow pool are used as the natural object. A photograph of ripples 300 is shown in FIG. 7A.

The first step is to photograph the natural ripples and convert them into grayscale images. For example, we will save the images as JPEG files. One frame of JPEG image data is made up of segments and image data, and grayscale images record gradations for each pixel.

The second process is to convert the JPEG image data into intermediate data. Specifically, the X and Y coordinate data of the image data are used as position coordinates. On the other hand, this is the process of converting the gradation data into Z coordinate data. For the whitest gradation, the Z coordinate is set to the highest value, and for the blackest gradation, the Z coordinate is set to the highest value. By setting in this way, it is possible to express light and dark with the mold. The three-dimensional data (x, y, z) 302 created in this way is shown in Figure 7B.

In the third step, swell data 304 is prepared to add swell to the water surface, and the visualization is shown in Figure 7C. The swell data 304 is generated in advance in (x, y, z) coordinates, and has the same area as the three-dimensional data 302.

The fourth step is combination data 306, which combines the ripple three-dimensional data (x, y, z) 302 and the waviness data (x, y, z) 304. By constructing a tool path from this combination data (x, y, z) 306, mold data for the ripples can be constructed.

Other natural objects that can be used other than water surfaces include rocks such as granite 308, plants such as leaves 310, leather such as tanned hide 312, wood grain 314, and Japanese paper 316, as shown in Figures 8A to 8E.

(Example)
Example 1
Example 1 according to the present invention will be described with reference to FIG. 9 showing an overall view and FIG. 10 showing a 120x enlarged view of the boundary. Example 1 shows a precision decorated resin molded product 400 made of ABS resin according to the present invention. The precision decorated resin molded product 400 has tool path marks 402 and 404 in two different directions on the surface. That is, the precision decorated resin molded product 400 is a precision decorated resin molded product molded with a mold having a first direction cutting portion and a second direction cutting portion. By implementing the present invention, a precision decorated resin molded product that reproduces carbon resin can be made. The gloss of the precision decorated resin molded product 400 is remarkable by using ABS resin.

Example 2
Example 2 according to the present invention will be described with reference to FIG. 11 showing an overall view and FIG. 12 showing a 120x enlarged view of the boundary. Example 2 shows a precision decorated resin molded product 410 made of polypropylene (PP) resin according to the present invention. The precision decorated resin molded product 410 has tool path marks 412 and 414 in two different directions on the surface. That is, the precision decorated resin molded product 410 is a precision decorated resin molded product molded with a mold having a first direction cutting portion and a second direction cutting portion. By implementing the present invention, a precision decorated resin molded product that reproduces carbon resin can be made. By using PP resin, the precision decorated resin molded product 410 has a characteristic of having a subdued gloss.

Example 3
Example 3 of the present invention will be described with reference to FIG. 13 showing an overall view and FIG. 14 showing a 120x enlarged view of the boundary. Example 3 shows a precision decorated resin molded product 420 according to the present invention. The precision decorated resin molded product 420 has a carbon-like design with tool path marks 422 and 424 in two different directions on the surface, a leaf-shaped design 426 with parallel vein-like cutting marks on the carbon-like design, and a mirror-like character design 428. That is, the precision decorated resin molded product 420 is a precision decorated resin molded product molded with a mold having a first direction cut portion, a second direction cut portion, and a non-cut portion. By implementing the present invention, precision decorated resin molded products of various designs can be made.

Example 4
Example 4 according to the present invention will be described with reference to FIG. 15 showing an overall view and FIG. 16 showing a 120-fold enlarged view of the boundary. Example 4 shows a precision decorated resin molded product 430 according to the present invention. The precision decorated resin molded product 430 has a carbon-like design in which tool path marks 432 and 434 in two different directions exist on the surface, a design 436 in which the shape is the silhouette of a car and the diagonal hairlines are arranged at intervals of 100 nm to 600 nm to realize rainbow colors, a design 438 in which the cherry fruit part is formed into a concentric circle shape by cutting the caps to realize rainbow colors, a character design 440 in which hairlines are engraved on the surface to realize rainbow colors, and a design 442 in which the shape of Yamagata Prefecture is shown in silhouette are displayed. Here, the hairline is a short linear linear mark made of a tool path mark. This refers to a state in which a plurality of these linear marks are engraved. That is, the precision decorated resin molded product 420 is a precision decorated resin molded product molded with a mold having a first direction cutting portion, a second direction cutting portion, and a non-cutting portion. By implementing the present invention, precision decorated resin molded products with a variety of designs can be produced.

Example 5
A fifth embodiment of the present invention will be described with reference to FIG. 17 showing an overall view and FIG. 18 showing a 120x enlarged view of the boundary. The fifth embodiment shows a precision decorated resin molded product 450 according to the present invention. The precision decorated resin molded product 450 has a checkered design formed on its surface, with tool path marks 452 and 454 in two different directions. The tool path marks 452 and 454 are cutting marks spaced at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in rainbow colors depending on the reflection angle. The tool path marks 452 and 454 are alternately arranged in a row in the horizontal direction in FIG. 17, and are not arranged in a row in the vertical direction in FIG. 17, with adjacent squares always shifting left and right.

That is, the precision decorated resin molded product 450 is a precision decorated resin molded product molded using a mold having a first direction cut portion and a second direction cut portion. By implementing the present invention, precision decorated resin molded products with a variety of designs can be produced.

Example 6
Example 6 according to the present invention will be described with reference to FIG. 19 showing an overall view and FIG. 20 showing a 120x enlarged view of the boundary. Example 6 shows a precision decorated resin molded product 460 according to the present invention. The precision decorated resin molded product 460 has a checkered design formed on the surface, in which tool path marks 462, 464, 466 and 468 exist in two different directions. The tool path marks 462, 464, 466 and 468 are cutting marks arranged at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in rainbow colors depending on the reflection angle. The tool path marks 462, 464, 466 and 468 are arranged alternately in a line in the diagonal direction in FIG. 19, and are arranged alternately in a line in the intersecting diagonal direction and are in contact with each other.

That is, the precision decorated resin molded product 460 is a precision decorated resin molded product molded using a mold having a first direction cut portion and a second direction cut portion. By implementing the present invention, precision decorated resin molded products with a variety of designs can be produced.

(Example 7)
Example 7 according to the present invention will be described with reference to FIG. 21 showing an overall view and FIG. 22 showing a 120-fold enlarged view of the boundary. Example 7 shows a precision decorated resin molded product 470 according to the present invention. The precision decorated resin molded product 470 has a surface on which a plurality of S-shaped patterns 472 are arranged in a row in the horizontal direction, and a plurality of inverted S-shaped patterns 474 are arranged in a row in the horizontal direction and symmetrically arranged at both ends, and the S-shaped patterns 472 are arranged in a row in the horizontal direction adjacent to the symmetrically arranged plurality of inverted S-shaped patterns 474 arranged in a row in the horizontal direction. Here, the surfaces of the S-shaped patterns 472 and the inverted S-shaped patterns 474 have a plurality of S-shaped and inverted S-shaped tool path marks, respectively. These tool path marks are cutting marks arranged at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in rainbow colors depending on the reflection angle.

That is, the precision decorated resin molded product 470 is a precision decorated resin molded product molded using a mold having multiple cutouts with curved portions. By implementing the present invention, precision decorated resin molded products with a variety of designs can be produced.

(Example 8)
The hexagonal hand plate scanning line machining of the eighth embodiment of the present invention will be described with reference to FIG. 23 showing an overall view, FIG. 24 showing a 120 times enlarged view of the boundary, and FIG. 25 showing a block diagram. The eighth embodiment shows a precision decorated resin molded product 480 according to the present invention. The precision decorated resin molded product 480 is a molded product covered with a shape carved so as to cover the surface with six equilateral triangles 482, 484, 486, 488, 490, and 492. The feature of this embodiment is that, as shown in FIG. 24, the tool path of the cutting tool during mold manufacturing is not dependent on the shape of a regular hexagon, and in this photograph, when a tool path mark 494 is made from the left to the right direction of the front, the next tool path mark 496 is configured to move from the right to the left direction of the front, and the adjacent tool paths are straight lines over the entire figure, and the adjacent tool path marks are configured to be parallel. This processing method is called scanning line processing, and since the tool movement time can be utilized for both the forward and backward travel, the processing time is halved compared to one-way processing. In addition, the tool path marks are cut at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in rainbow colors depending on the reflection angle. Rainbows are particularly likely to occur in this embodiment.

Also, when reflected, the triangles light up in alternate rows, but the triangles above and below light up, creating a diamond shape as shown in Figure 23.

That is, the precision decorated resin molded product 480 is a precision decorated resin molded product molded using a mold having multiple cutouts with curved portions. By implementing the present invention, precision decorated resin molded products with a variety of designs can be produced.

As for the machining process of the mold used in Example 8, as the first stage of machining, as shown in Figure 25, contour machining is performed as rough machining by moving the tool path along the contour lines of the hexagonal pyramid portion (A2).

The second stage of processing involves scanning line processing as a semi-finishing step (A4).

The third stage of processing involves finishing scanning line processing (A6).

(Example 9)
The hexagonal hand plate spiral processing of the ninth embodiment of the present invention will be described with reference to FIG. 26 showing an overall view, FIG. 27 showing a 120 times enlarged view of the boundary, and FIG. 28 showing a block diagram. The ninth embodiment shows a precision decorated resin molded product 500 according to the present invention. The precision decorated resin molded product 500 is a molded product covered with a shape carved so as to cover the surface with six equilateral triangles 502, 504, 506, 508, 510, and 512. The feature of this embodiment is that, as shown in FIG. 27, the tool path of the cutting tool during the manufacturing of the mold is made along the shape of a regular hexagon, particularly along the contour lines, and in this photograph, a tool path mark 514 is made from the upper right corner of the front to the lower right, that is, by changing the direction at the same angle after moving a certain distance, a regular polygon is formed in a spiral shape with a continuous line. Specifically, the next tool path mark 516 is configured to move from the center right of the front to the lower left, and adjacent tool path marks form a hexagon in a spiral swirl shape over the entire figure, and adjacent tool path marks are configured to be parallel. This processing method is called scanning line processing, and since the tool movement time can be utilized for the forward and backward round trips, the processing time is halved compared to one-way processing. In addition, the cutting marks are spaced 100 nm to 600 nm apart, and when light is irradiated, the reflected light shines in rainbow colors depending on the reflection angle. Rainbows are particularly likely to occur in this embodiment.

Another characteristic of this device is that when it is reflected, the triangles light up in alternating rows, but the triangles above and below do not light up, and only one of the triangles lights up, as shown in Figure 26, for example.

In other words, the precision decorated resin molded product 500 is a precision decorated resin molded product molded using a mold having multiple cutouts with curved portions. By implementing the present invention, precision decorated resin molded products with a variety of designs can be produced.

As for the machining process of the mold used in Example 9, as the first stage of machining, as shown in Figure 28, contour machining is performed as rough machining by moving the tool path along the contour lines of the hexagonal pyramid portion (B2).

The second stage of processing involves scanning line processing as a semi-finishing step (B4).

The third stage of processing involves finishing with 3D equal pitch processing (B6).

(Example 10)
Example 10 of a stone pattern molded product according to the present invention will be described with reference to Fig. 29 showing an overall view, Fig. 30 showing a 120x enlarged view of the boundary, and Figs. 31 to 34 showing a method for manufacturing a mold. Example 10 shows a precision-decorated resin molded product 520 according to the present invention. Precision-decorated resin molded product 520 is a molded product that is produced by scanning a natural product to manufacture a mold, and then molded based on the mold.

The manufacturing method of a mold for molding a precision decorated resin molded product 520 is described as follows. First, an example of a natural object to be scanned in the first step is granite 308 shown in Figure 8A.

The granite selected in the second step is 3D scanned to obtain position and height information for the surface irregularities. Figure 32 shows the data actually obtained. The y coordinate is fixed and the data is displayed in terms of x and z coordinates. Figure 31 shows an image of this data for all y coordinates.

In the third step, the Z coordinate data of the 3D scan data obtained in the second step is converted by a specific proportional coefficient. The converted data is shown in Figure 33.

In the fourth step, a tool path is created based on the pre-machining data obtained in the second step, and the mold surface is machined (Figure 34C2).

In the fifth step, a blasting process is performed on the mold that was machined in the fourth step (Figure 34C4).

In the sixth step, the surface of the blasted mold is additionally machined based on the data obtained from the machining in the Z direction in the third step (Fig. 34C6). For this reason, the portion indicated by 522 in Fig. 33 is further cut. In addition, a portion of 522 in Fig. 29 is partially mirror-finished.

In the seventh step, injection molding is performed using the mold completed in the sixth step. This results in the precision decorated resin molded product 520 shown in the tenth embodiment of the present invention.

By implementing this invention, it is possible to create precision decorated resin molded products with a wide variety of designs.

Example 11
Example 11 according to the present invention will be described with reference to FIG. 35 showing an overall view. Example 11 shows a precision decorated resin molded product 530 according to the present invention. The precision decorated resin molded product 530 has concentric circular boundary lines 538, 540, 542, 544, 546, 548, 550 and radial boundary lines 532, 534, 536 in the axial direction for a circular pattern, and is configured so that adjacent regions are processed by different processing methods. As one method, the entire circumference can be processed by changing the cutting direction by 90 degrees in adjacent regions. Each of the tool path marks is present in the region and is a cutting mark arranged at intervals of 100 nm to 600 nm, and when light is irradiated, the reflected light shines in rainbow colors depending on the reflection angle. The tool path marks are arranged alternately in a row in the horizontal direction in FIG. 35, and are not arranged in a row in the vertical direction in FIG. 35, so that adjacent squares are always shifted left and right and in contact with each other.

2 Interior parts 4 Dashboard 6 Instrument panel 8 Center cluster 10 Steering wheel 12 Meter 13 Shift lever 22 Machining center 24 Machine tool body 26 Control device 28 Workpiece 30 Cutting tool 32 Spindle 40 Mold 50 Mold 52 Mirror surface portion 54 Cutting portion 56 Tool path 58 Cusp 60 Mold 62 Textured portion 63 Wrinkle pattern 64 Cutting portion 68 Cusp 70 Mold 72 Photo-etched portion 73 Etched recess pattern 74 Cutting portion 78 Cusp 80 Mold 82 Blasted portion 83 Blasted recess pattern 84 Cutting portion 88 Cusp 90 Mold 92 Laser-processed portion 93 Laser recess pattern 94 Cutting portion 98 Cusp 100 Mold 102 Electric discharge-processed portion 103 Electric discharge-processed pattern 104 Cutting portion 108 Cusp 110 Mold 114 Cutting portion 116 Tool path 120 Mold 122 First pitch cutting portion 124 Second pitch cutting portion 126 Tool path 128 Cusp 130 Tool path 132 Cusp 140 Mold 142 First directional cutting portion 144 Second directional cutting portion 146 Tool path 148 Cusp 150 Tool path 152 Cusp 160 Mold 162 Straight line cutting portion 164 Curved line cutting portion 166 Tool path 168 Cusp 170 Tool path 172 Cusp 180 Mold 182 First curvature curve cutting portion 184 Second curvature curve cutting portion 186 Tool path 188 First curvature cusp 188 Cusp 190 Tool path 192 Second curvature cusp 200 Mold 202 Straight line cutting portion 204 Contour line parallel cutting portion 206 Tool path 208 Cusp 210, 212, 214 Contour line 216, 218 Tool path 220 Mold 222 Straight cutting portion 224 Contour non-parallel cutting portion 228 Cusp 230, 232, 234 Contour lines 236, 238, 240, 242, 244, 246, 248, 250 Tool path 260 Die 262, 264, 266, 268, 270, 272, 274, 276 Circular boundary line 261, 263, 265 Radial boundary line 278 First direction cutting portion 280 Second direction cutting portion 290 Die 292, 294 Tool path 296 Cusp 300 Ripple 302 Three-dimensional data 304 Waviness data (x, y, z)
306 combination data (x, y, z)
308 Rocks such as granite 310 Plants such as tree leaves 312 Leather such as tanned leather 314 Wood grain 316 Japanese paper 400 Precision decorative resin molded product 402, 404 Tool path marks 410 Precision decorative resin molded product 412, 414 Tool path marks 420 Precision decorative resin molded product 422, 424 Tool path marks 426 Leaf-shaped design 428 Letter design 420 Precision decorative resin molded product 450 Precision decorative resin molded product 430 Precision decorative resin molded product 432, 434 Tool path marks 436 Design 438 Design 440 Letter design 442 Design 452, 454 Tool path marks 450 Precision decorative resin molded product 460 Precision decorative resin molded product 462, 464, 466 and 468 Tool path marks 470 Precision decorative resin molded product 472 S-shaped pattern 474 Inverted S-shaped pattern 480 Precision decorated resin molded product 482, 484, 486, 488, 490, 492 Equilateral triangle 494 Tool path mark 496 Tool path mark 500 Precision decorated resin molded product 502, 504, 506, 508, 510, 512 Equilateral triangle 514 Tool path mark 516 Tool path mark 520 Precision decorated resin molded product 520 Precision decorated resin molded product 522 Mirror-finished portion 530 Precision decorated resin molded product 538, 540, 542, 544, 546, 548, 550 Circular boundary line 532, 534, 536 Radial boundary line

Claims (17)

In precision-decorated resin molded products formed by injection molding in a mold,
The surface has at least two regions,
The area is made up of a non-cutting resin surface made of a mold surface processed by non-cutting processing technology, and
a first machined resin surface formed by a mold surface formed by a first machining technique;
A precision decorated resin molded product having at least two or more regions of a second cut processed resin surface formed by a mold surface formed by a second cut processing technique under different conditions from the first cut processed resin surface,
A precision-decorated resin molded product, characterized in that the first cutting processing technique or the second cutting processing technique has a cutting direction of a cutting tool of the first cutting processing technique different from the cutting direction of a cutting tool of the second cutting processing technique. The precision-decorated resin molded product according to claim 1, wherein the non-cutting processing technique is mirror polishing, embossing, photoetching, blasting, laser processing, electrical discharge processing, or a combination thereof. The precision decorated resin molded product according to claim 1 or 2, characterized in that the first cutting technique or the second cutting technique uses the same cutting tool, but the pitch of adjacent tool paths when the cutting tool moves is different. The precision decorated resin molded product according to any one of claims 1 to 3, characterized in that in the first cutting technique or the second cutting technique, the cutting tool of the first cutting technique engraves in a straight line, and the cutting tool of the second cutting technique engraves in a curved line. The precision-decorated resin molded product according to any one of claims 1 to 3, characterized in that in the first cutting processing technique or the second cutting processing technique, the cutting tool of the first cutting processing technique is engraved in a curved shape , and the cutting tool of the second cutting processing technique is also engraved in a curved shape having a different curvature . A precision-decorated resin molded product according to any one of claims 1 to 3, characterized in that the cutting direction of either the first cutting technique or the second cutting technique is parallel to the contour lines. A precisely decorated resin molded product according to any one of claims 1 to 3, characterized in that the cutting direction of either the first cutting technique or the second cutting technique is non-parallel to the contour lines. In precision-decorated resin molded products formed by injection molding in a mold,
The surface has at least two regions,
This precision decorative resin molded product is created by forming multiple areas by moving the processing tool a certain distance and then changing direction at the same angle to form a regular polygon in a spiral shape with a continuous line. In precision-decorated resin molded products formed by injection molding in a mold,
A precision-decorated resin molded product that forms multiple regions by measuring the surface of a naturally occurring natural product over an arbitrary area as three-dimensional coordinates, determining a reference plane for that surface in advance, converting the three-dimensional coordinates into emphasized three-dimensional coordinates by multiplying only the numerical values in the height direction from the reference plane by a specific coefficient, and forming a surface region using the emphasized three-dimensional coordinates with a mold. A precisely decorated resin molded product according to any one of claims 1 to 7, characterized in that letters, figures or a combination thereof are formed on different resin surfaces. A precisely decorated resin molded product according to any one of claims 1 to 8, characterized in that the tool movement pitch when cutting each area of the mold is such that the product has a white luster after molding. A precisely decorated resin molded product according to any one of claims 1 to 9, characterized in that the tool movement pitch when cutting each area of the mold is such that the product will have an iridescent luster after molding. The precision-decorated resin molded product according to claim 8, characterized in that the regular polygon is a hexagon. The precision-decorated resin molded product according to claim 9, characterized in that the natural material is stone. In a mold for forming a precision decorated resin molded product formed by injection molding into a mold,
The surface comprises at least two regions,
The area is made up of the non-cut resin surface of the mold, which is processed using non-cutting processing technology, and
a first machined resin surface of a mold surface formed by a first machining technique;
A mold for forming a precision decorated resin molded product, comprising at least two or more regions of a second cut resin surface of a mold surface formed by a second cut processing technique under conditions different from those of the first cut resin surface,
A mold for forming precision decorated resin molded products, characterized in that the first cutting processing technique or the second cutting processing technique has a cutting direction of a cutting tool of the first cutting processing technique different from the cutting direction of a cutting tool of the second cutting processing technique. In a precision decorative resin molding method in which a product is formed by injection molding into a mold,
The surface comprises at least two regions,
The area is made up of a non-cutting resin surface made of a mold surface processed by non-cutting processing technology, and
a first machined resin surface formed by a mold surface formed by a first machining technique;
A precision decorative resin molding method having at least two or more regions of a second cut-machined resin surface formed by a mold surface formed by a second cutting technique under conditions different from those of the first cut-machined resin surface,
The precision decorative resin molding method is characterized in that the first cutting processing technique or the second cutting processing technique has a cutting direction of a cutting tool of the first cutting processing technique different from the cutting direction of a cutting tool of the second cutting processing technique. A method for manufacturing a mold for forming a precision decorated resin molded product formed by injection molding into a mold, comprising the steps of:
The surface comprises at least two regions,
The area is made up of the non-cut resin surface of the mold, which is processed using non-cutting processing technology, and
a first machined resin surface of a mold surface formed by a first machining technique;
A method for manufacturing a mold for forming a precision decorated resin molded product, the mold surface having at least two or more regions of a second cut-processed resin surface formed by a second cut processing technique under different conditions from the first cut-processed resin surface,
A method for manufacturing a mold for forming precision decorated resin molded products, characterized in that the first cutting processing technique or the second cutting processing technique has a cutting direction of a cutting tool of the first cutting processing technique different from the cutting direction of a cutting tool of the second cutting processing technique.