U.S. patent application number 12/655030 was filed with the patent office on 2010-04-29 for method of duplicating nano pattern texture on object's surface by nano imprinting and electroforming.
This patent application is currently assigned to EMOT CO., LTD.. Invention is credited to Jun Sang Jeong, Kyung Wook Lee, Kyung Yul Lee.
Application Number | 20100101961 12/655030 |
Document ID | / |
Family ID | 40185778 |
Filed Date | 2010-04-29 |
United States Patent
Application |
20100101961 |
Kind Code |
A1 |
Lee; Kyung Wook ; et
al. |
April 29, 2010 |
Method of duplicating nano pattern texture on object's surface by
nano imprinting and electroforming
Abstract
Disclosed is a method of duplicating a nano-pattern texture of
the surface of an object through electroforming using an imprint
mold, including selecting the object having the surface texture to
be duplicated; disposing the selected object and pre-treating the
surface thereof; nano-imprinting the surface of the pretreated
object, thus duplicating it on a plastic mold; metallizing the
surface of the plastic mold through vapor deposition, and
performing electroforming, thus manufacturing metal module master
molds; trimming the edges of the metal module master molds,
performing micro-processing, connecting the metal module master
molds, and then performing electroforming, thus manufacturing a
large-area metal unit master mold; and electroforming the metal
unit master mold, thus producing a duplicate having the surface
texture, thus exhibiting an effect in which the skin of a selected
natural object can be duplicated on metal having a uniform
thickness.
Inventors: |
Lee; Kyung Wook; (Ansan,
KR) ; Lee; Kyung Yul; (Bucheon, KR) ; Jeong;
Jun Sang; (Daejeon, KR) |
Correspondence
Address: |
LRK Patent Law Firm
1952 Gallows Rd, Suite 200
Vienna
VA
22182
US
|
Assignee: |
EMOT CO., LTD.
Ansan
KR
|
Family ID: |
40185778 |
Appl. No.: |
12/655030 |
Filed: |
December 22, 2009 |
Current U.S.
Class: |
205/69 ; 205/67;
205/72 |
Current CPC
Class: |
C25D 1/10 20130101; B29C
33/3857 20130101; B23P 15/24 20130101; C25D 1/006 20130101; C23C
18/1657 20130101 |
Class at
Publication: |
205/69 ; 205/67;
205/72 |
International
Class: |
B41N 1/04 20060101
B41N001/04; C25D 1/00 20060101 C25D001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 28, 2007 |
KR |
10-2007-0064153 |
Claims
1. A method of duplicating a nano-pattern texture of a surface of
an object through electroforming using an imprint mold, comprising:
selecting the object having the surface texture to be duplicated;
disposing the selected object and pretreating a surface thereof;
nano-imprinting the surface of the pretreated object, thus
duplicating it on a plastic mold; metallizing a surface of the
plastic mold through vapor deposition and performing
electroforming, thus manufacturing metal module master molds;
trimming edges of the metal module master molds, performing
micro-processing, connecting the metal module master molds, and
then performing electroforming, thus manufacturing a large-area
metal unit master mold; and electroforming the metal unit master
mold, thus producing a duplicate having the surface texture.
2. The method according to claim 1, further comprising subjecting
the duplicate having the surface texture to either vapor deposition
or painting for coloring treatment and to coating with a protective
film.
3. The method according to claim 1, wherein the object is selected
from among natural materials, including animals, plants, insects,
and minerals, and artificial materials, including processed
materials, woven fabric, and artwork.
4. The method according to claim 1, wherein the pretreating
comprises subjecting the surface of the selected object to washing,
drying and then nano-thin film treatment to block transfer of
impurities so as to facilitate separation of a nano-imprint
mold.
5. The method according to claim 1, wherein the nano-imprinting
comprises subjecting the surface of the object, which has been
subjected to thin film treatment, to PDMS molding, to realize
duplication on the mold.
6. The method according to claim 5, wherein the nano-imprinting
further comprises hot embossing with a thermoplastic polymer film,
to realize duplication on the mold.
7. The method according to claim 5, wherein the nano-imprinting
further comprises either UV imprinting or roll imprinting.
8. The method according to claim 1, wherein the nano-imprinting
comprises a combination of UV imprinting and roll imprinting.
9. The method according to claim 1, wherein the nano-imprinting
comprises a combination of hot embossing and roll imprinting.
10. The method according to claim 1, wherein the metallizing
further comprises subjecting the surface of the mold to either
spraying or wet silver curing.
11. The method according to claim 1, wherein the micro-processing
comprises scanning the surface of the object to be duplicated to
set a predetermined standard pattern for connection of the molds
and then performing two-dimensional or three-dimensional
micro-processing.
12. The method according to claim 11, wherein the micro-processing
further comprises nano-processing.
13. The method according to claim 1, wherein the electroforming is
performed through either electroplating or electroless plating.
14. The method according to claim 13, wherein the electroplating or
electroless plating facilitates separation of the duplicate through
thin film treatment.
15. The method according to claim 1, wherein the large-area unit
master mold is manufactured by trimming the edges of the module
master molds, performing two-dimensional or three-dimensional
processing to impart a standard pattern, and connecting trimmed
portions of the module master molds.
16. The method according to claim 15, wherein the connecting the
module master molds is performed by adhering or welding the module
master molds.
17. The method according to claim 1, wherein the unit master mold
is manufactured by performing electroforming in a state in which
the module master molds are connected to form a large area, thus
obtaining a metal unit master mold.
18. The method according to claim 1, wherein the producing the
duplicate comprises electroforming the metal unit master mold, thus
producing a duplicate made of metal having the surface texture.
19. A method of duplicating a nano-pattern texture of a surface of
an object using an imprint mold, comprising: selecting the object,
pretreating a surface thereof, performing nano-imprinting to
manufacture a plastic mold, metallizing the mold through vapor
deposition, and performing electroforming, thus manufacturing metal
module master molds; trimming edges of the metal module master
molds, performing two-dimensional or three-dimensional
micro-processing to impart a standard pattern set through surface
scanning, connecting the metal module master molds, and performing
electroforming, thus manufacturing a large-area metal unit master
mold; and producing a duplicate having the surface texture from the
unit master mold, and subjecting it to coloring and coating.
20. The method according to claim 19, wherein the standard pattern
is shown to be similar to the surface of the object by scanning the
surface of the selected object and subjecting the mold to
two-dimensional or three-dimensional micro-processing.
21. The method according to claim 19, wherein the duplicate is
duplicated in plastic.
22. The method according to claim 17, wherein the object is
selected from among natural materials, processed natural materials,
processed materials, artwork, and artificial materials.
23. The method according to claim 2, wherein the nano-imprinting
comprises a combination of UV imprinting and roll imprinting.
24. The method according to claim 2, wherein the nano-imprinting
comprises a combination of hot embossing and roll imprinting.
25. The method according to claim 2, wherein the large-area unit
master mold is manufactured by trimming the edges of the module
master molds, performing two-dimensional or three-dimensional
processing to impart a standard pattern, and connecting trimmed
portions of the module master molds.
26. The method according to claim 25, wherein the connecting the
module master molds is performed by adhering or welding the module
master molds.
27. The method according to claim 2, wherein the producing the
duplicate comprises electroforming the metal unit master mold, thus
producing a duplicate made of metal having the surface texture.
Description
TECHNICAL FIELD
[0001] The present invention relates to the nano-duplication of the
surface of an object, and more particularly, to a method of
duplicating the nano-pattern of the surface of an object, by
duplicating the fine and beautiful surface of an object, which is
to be duplicated, using nano-imprinting and electroforming, thus
realizing an original texture.
BACKGROUND ART
[0002] Generally, the skins or surfaces of objects naturally
present in the natural world, such as plants, insects, leather,
minerals, trees, fiber, and fabric, have very beautiful and soft
structures and textures and exhibit natural colors, and thus
research and development into the application thereof to decorate
the outer appearances of mass-produced industrial products is
ongoing. In particular, because mobile communication portable
terminals, PDAs, or notebook computers, which are expensive and are
manufactured to be luxurious, should always be carried, the surface
thereof is required to have low abrasion and be easy to maintain,
and further, because they are shown to other persons, the outer
appearance thereof is required to have a soft and luxurious texture
or feel.
[0003] It is typical for metal material to be used to decrease the
abrasion of a surface and for natural material to be used to impart
a soft feel. Therefore, in order to develop an outer appearance or
surface imparting a soft feel using metal material having low
abrasion, lots of time and money are invested. Meanwhile,
duplication methods in plastic are being developed.
[0004] The case where an object having a predetermined pattern to
be duplicated is soft enables complicated and fine surface
duplication but makes it difficult to manufacture a mold for use in
such duplication. Further, although an etching process including
photolithography and chemical etching may be applied to produce
complicated and fine patterns, it is unsuitable for mass
production.
[0005] In the case of plastic dolls, wire telephones, automobiles
or the like, a molding technique is applied at high pressure using
a press so that the same shape or outer appearance is
mass-duplicated, whereas, in the case of the skin of insects,
plants, processed leather, minerals, fiber, and fabric, repeated
duplication of a fine surface texture on the nanometer scale cannot
be realized by the magnitude of the pressure of the press, and
thus, desired colors and patterns must be realized through
additional surface treatment.
[0006] However, such additional surface treatment is also
problematic in that it is difficult to realize a good texture and
structure, as in the skin of the insects, plants, processed
leather, minerals, fiber, and fabric.
DISCLOSURE
Technical Problem
[0007] Accordingly, the present invention provides a method of
duplicating the texture of the surface of an object, such as an
animal, plant, mineral, fabric, or wood, on metal or plastic to
thus realize the same texture, and specifically, a method of
duplicating the nano-pattern of the surface of an object so that
metal or plastic is imparted with the surface texture of the
selected object using a nano-imprint plastic mold and an
electroformed master mold.
[0008] In addition, the present invention provides a method of
duplicating the nano-pattern of the surface of an object by
scanning the surface of an object to be duplicated, performing
two-dimensional (2D) or three-dimensional (3D) micro- or
nano-technology, thus forming a standard pattern, and connecting
the edges of nano-imprint module master molds to impart the
standard pattern, thus forming a large-area master mold having a
desired size.
Technical Solution
[0009] According to the present invention, a method of
electroforming the surface texture of an object using an imprint
mold may comprise selecting the object having the surface texture
to be duplicated; disposing the selected object and pretreating the
surface thereof; nano-imprinting the surface of the pretreated
object, thus duplicating it on a plastic mold; metallizing the
surface of the plastic mold through vapor deposition and performing
electroforming, thus manufacturing metal module master molds;
trimming the edges of the metal module master molds, performing
micro-processing, connecting the metal module master molds, and
then performing electroforming, thus manufacturing a large-area
metal unit master mold; and electroforming the metal unit master
mold, thus producing a duplicate having the surface texture.
[0010] In addition, a method of duplicating the surface texture of
an object using an imprint mold may comprise selecting the object,
pretreating the surface thereof, nano-imprinting the pretreated
surface to manufacture a plastic mold, which is then metallized
through vapor deposition, and performing electroforming, thus
manufacturing metal module master molds; trimming the edges of the
metal module master molds, performing 2D or 3D micro-processing to
impart a standard pattern set through surface scanning, connecting
the metal module master molds, and performing electroforming, thus
manufacturing a large-area metal unit master mold; and producing a
duplicate having the surface texture from the unit master mold, and
coloring and coating it.
ADVANTAGEOUS EFFECTS
[0011] According to the present invention, the nano-pattern texture
of the surface of the selected object is nano-imprinted, thus
manufacturing module master molds, which are then subjected to 2D
or 3D edge processing and electroforming, thus manufacturing a
large-area unit master mold, from which the same texture can then
be duplicated on metal or plastic, thus realizing industrial
availability.
[0012] In addition, according to the present invention, because
electroforming is performed using the master mold having the
nano-pattern texture of the surface of the selected object, the
same texture can be duplicated on metal having a uniform thickness,
thus realizing industrial availability.
[0013] In addition, according to the present invention, the surface
of the selected object, having a beautiful and soft texture,
structure and color, can be mass-duplicated and mass-produced, thus
realizing convenient effects in industrial use.
DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a flowchart sequentially illustrating the process
of duplicating the nano-pattern texture of the surface of an object
according to the present invention;
[0015] FIG. 2 is a photograph illustrating a large-area master
mold, which is manufactured by subjecting a plurality of module
master molds, which are imprinted with the surface of natural
leather according to an embodiment of the present invention, to
edge processing;
[0016] FIG. 3 is a photograph, magnified 2.times., of the front
surface of natural leather, which is to be molded through
nano-imprinting, according to the embodiment of the present
invention;
[0017] FIG. 4 is a photograph, magnified 2.times., of the mold
which is nano-imprinted with the front surface of natural leather
according to the embodiment of the present invention;
[0018] FIG. 5 is a photograph, magnified 2.times., of the back
surface of natural leather, which is to be molded through
nano-imprinting, according to the embodiment of the present
invention;
[0019] FIG. 6 is a photograph, magnified 2.times., of the mold
which is nano-imprinted with the back surface of natural leather
according to the embodiment of the present invention; and
[0020] FIG. 7 is a photograph illustrating a final product having
the nano-pattern texture of the surface of the object, according to
the embodiment of the present invention, duplicated thereon.
MODE FOR INVENTION
[0021] Hereinafter, a detailed description will be given of a
method of duplicating the nano-pattern of the surface of an object
using electroforming according to the present invention, with
reference to the accompanying drawings.
[0022] In the present invention, FIG. 1 is a flowchart sequentially
illustrating the process of duplicating the nano-pattern of the
surface of an object according to the present invention, FIG. 2 is
a photograph illustrating a plastic mold which is nano-imprinted
with the surface of natural leather according to an embodiment of
the present invention, FIG. 3 is a photograph, magnified 2.times.,
of the front surface of natural leather to be molded through
nano-imprinting according to the embodiment of the present
invention, FIG. 4 is a photograph, magnified 2.times., of the mold
which is nano-imprinted with the front surface of natural leather
according to the embodiment of the present invention, FIG. 5 is a
photograph, magnified 2.times., of the back surface of natural
leather to be molded through nano-imprinting according to the
embodiment of the present invention, FIG. 6 is a photograph,
magnified 2.times., of the mold which is nano-imprinted with the
back surface of natural leather according to the embodiment of the
present invention, and FIG. 7 is a photograph illustrating the
state of a final product having the surface texture of the object
according to the embodiment of the present invention, duplicated
thereon.
[0023] In the description of the embodiment of the present
invention, the drawings and explanation of techniques which are not
directly concerned with the present invention or are well-known in
the art are omitted, so that the major point of the present
invention can be clearly and definitely communicated.
[0024] As illustrated in FIG. 1, the method of duplicating the
nano-pattern texture of the surface of the object according to the
embodiment of the present invention comprises selecting an object
to be duplicated; disposing and washing the object; subjecting the
object to nano-imprinting to thus duplicate it on a plastic mold;
subjecting the plastic mold to vapor deposition and electroforming
to thus manufacture metal module master molds; trimming the edges
of the module master molds, performing micro- or nano-processing,
connecting the module master molds, and performing electroforming,
thus manufacturing a large-area metal unit master mold; producing a
duplicate having the nano-pattern surface texture from the unit
master mold; and subjecting the duplicate having the nano-pattern
surface texture to vapor deposition or printing and coating.
[0025] Preferably, the method of the present invention further
comprises subjecting the object to be duplicated to pretreatment,
such as washing and drying, and then to nano-separation film
treatment for electroforming so that the transfer of impurities is
blocked and the duplicate is easily separated.
[0026] The nano-imprinting for the duplication of the surface
texture of the object is performed using a thermoplastic polymer
film, which is a kind of plastic.
[0027] The nano-imprinting includes PDMS molding, UV imprinting,
hot embossing, and roll imprinting, and is performed through either
a casting process or an injection process.
[0028] The nano-imprinting enables duplication on the mold through
hot embossing with a thermoplastic polymer film.
[0029] The nano-imprinting includes a combination of UV imprinting
and roll imprinting, or a combination of hot embossing and roll
imprinting.
[0030] The metallization of the surface of the mold is performed
using any one process selected from among vapor deposition,
spraying, and wet silver curing.
[0031] The electroforming is performed through electroplating or
electroless plating.
[0032] The unit master mold is formed to have an enlarged area by
trimming the edges of the module master molds, subjecting
predetermined widths of the trimmed portions of the module master
molds to 2D or 3D micro- or nano-processing to impart a
predetermined standard pattern for connection designed through 2D
or 3D scanning of the surface of the object to be duplicated,
arranging the module master molds, and connecting them through
adhesion or welding.
[0033] The duplicate includes products obtained by subjecting the
completed metal unit master mold to metal electroforming or plastic
injection or extrusion.
[0034] In addition, the method of duplicating the nano-pattern
texture of the surface of the object with the imprint mold
comprises pretreating the surface of a selected object,
nano-imprinting the object to thus manufacture a mold, which is
then subjected to deposition for metallization and to
electroforming, thus manufacturing metal module master molds;
trimming the edges of the module master molds, performing 2D or 3D
micro-processing to impart a standard pattern, connecting the
module master molds, and performing electroforming, thus
manufacturing a large-area unit master mold; and coloring and
coating the duplicate having the nano-pattern surface texture
produced from the unit master mold.
[0035] Below, the method of duplicating the nano-pattern texture of
the surface of the object according to the embodiment of the
present invention is specifically described in conjunction with the
appended drawings.
[0036] The electroforming process (galvanoplastics) is a technique
for duplicating the same surface texture as that of the pattern
using electroplating, and performs electrodeposition coating of a
thin film of metal ions through electroplating, thus forming a
model having the same surface as the pattern. The pattern may be
non-metallic or metallic. The non-metallic pattern is pretreated
with a separation film or the like, after which the surface thereof
is coated with graphite powder or copper powder or with a thin film
made of gold or silver, in order to impart conductivity thereto.
The surface of the metallic pattern is coated with a thin film made
of oxide or graphite powder, that is, a separation film, after
which the metallic pattern is placed in an electrolytic bath and is
then electrodeposited with a metal component under the flow of
current. The metal electrodeposited on the surface of the pattern
is removed, thereby obtaining a negative mold having a reversed
form. Examples of the metal for electrodeposition include copper,
nickel, iron, etc. The reversed form may be used as it is, or
alternatively, the surface thereof may be repeatedly subjected to
separation film treatment and electroforming, thereby duplicating
the same product as the pattern.
[0037] Generally, plating and electroforming are distinguished from
each other depending on the thickness of the plating layer. For
example, the plating layer resulting from plating is
0.001.about.0.05 mm thick, and the plating layer resulting from
electroforming is 0.025.about.25 mm thick.
[0038] The electroforming process is characterized in that various
physical properties may be obtained through adjustment of the type
and hardness of metal depending on the electrolysis conditions,
there is little difference between the duplicate and the pattern,
surface duplication is realized with high fidelity, almost no
limitations are imposed on the size and shape of the duplicate,
high-purity metal products can be obtained, both one-off production
and mass production are possible, and seamless tubes or hollow
products can be manufactured. However, the electroforming process
is disadvantageous because a long period of time is required
therefor, unnecessary shapes or minor shapes, such as scratches,
may also be duplicated, high technical knowledge for manufacture of
the product and design of the pattern is needed, it is difficult to
obtain a product having a uniform thickness in the presence of
severe roughness and curvature, and high expense incurs.
[0039] Polydimethylsiloxane (PDMS) is a kind of polymer material
suitable for a molding process which facilitates the mass
production of fine duplicate products on a nanometer scale of 100
nm or less.
[0040] The PDMS, which is a kind of plastic, may be manufactured in
the form of a negative mold by mixing a raw material thereof with a
curing agent and sintering the mixture in a positive mold having a
predetermined shape. When such a PDMS mold is used, a desired
nano-pattern may be realized on the surface of another metal using
the nano-pattern which is nano-imprinted on the mold, as in the
relationship between a stamp and ink. This method is referred to as
soft lithography. Instead of the above positive mold, a negative
mold may be used.
[0041] The nano-imprinting process is a technique for duplicating
the nano-pattern surface by placing a stamp having nano-sized
surface roughness on a polymer resin-applied substrate and then
pressing it thereon, and is classified into hot embossing using
heat and UV imprinting to cure the polymer resin on the substrate
using UV light. In addition, for mass production, roll imprinting
using a roll-shaped stamp is an example thereof. For example, when
a photosensitive material such as SU-8 is applied on a silicon
wafer and is then patterned using a photomask, a master may be
obtained. When PDMS is subjected to casting or injection using the
master as a mold and then to sintering, the PDMS mold, functioning
as a stamp, may be completed. Soft lithography using the PDMS stamp
thus obtained includes microcontact printing, replica molding,
microtransfer molding, micromolding using capillaries, etc.
[0042] PDMS is advantageous because it is non-toxic and transparent
and has very low autofluorescence, and is particularly useful for
biological experiments requiring frequent fluorescent measurements.
Further, when the surface of the completed PDMS is plasma-treated,
surface oxidation occurs to thus realize hydrophilic surface
properties, and simultaneously, the above PDMS may be connected
with glass or another PDMS material, and therefore it may be widely
utilized for the manufacture of microfluidic channels.
[0043] The vapor deposition process is a technique for vaporizing
an object to thus deposit it on the surface of another object, and
includes chemical vapor deposition (CVD) and physical vapor
deposition (PVD). CVD serves to form a film on the surface of an
object using a chemical reaction. For instance, CVD may be applied
as in the formation of a film through the control of a chemical
reaction on a semiconductor wafer.
[0044] Examples of the CVD include low pressure CVD (LPCVD), plasma
enhanced CVD (PECVD), and atmospheric pressure CVD (APCVD), and
examples of the PVD include evaporation using metal vapor and
sputtering, in which physical impacts are applied to material. In
addition, atomic layer deposition (ALD) is useful.
[0045] Although it is typically difficult to industrially copy
beautiful and soft textures, structures and colors of the skins or
surfaces of objects, such as leather, fabric, plants, trees,
minerals, or insects, which are present naturally in the natural
world or are present artificially through processing and industrial
arts, the present invention is intended to repeatedly duplicate a
nano-pattern texture similar to that of the surface of the pattern
through 2D or 3D scanning, micro- or nano-processing, arrangement,
connection, and electroforming.
[0046] Among the above objects, any object to be duplicated is
selected, for example, leather is selected (S100), after which the
surface of the selected object is washed to remove impurities, and
the object is selectively disposed in a planar or curved state, and
is then subjected to nano-separation film surface treatment (S110).
The separation film treatment performed to form a thin film on the
surface of the washed object, so that an imprint mold is easily
separated therefrom.
[0047] The surface of the object is subjected to nano-imprinting,
such as PDMS molding or hot embossing, thus manufacturing a mold
(S120).
[0048] The nano-imprinting includes one or more selected from among
PDMS molding, hot embossing, UV (UltraViolet) imprinting, and roll
imprinting, and may be performed using either a casting process or
an injection process.
[0049] For example, the nano-imprinting may be performed through
any one selected from among PDMS molding, hot embossing with a
thermoplastic polymer film, UV imprinting, roll imprinting, a
combination of UV imprinting and roll imprinting, and a combination
of hot embossing and roll imprinting.
[0050] Nano-imprinting enables the manufacture of the mold for the
duplication of a fine nano-pattern surface, and plays a role in
imprinting a nano-structured pattern on the surface of the mold,
like the concept of stamping paper. Nano-imprinting materials
include thermoplastic, thermosetting, and UV-curable resist
material, in addition to PDMS. Although nano-imprinting is similar
to the basic principle of polymer molding, it is quite different
from a conventional imprinting process because microphysical
phenomena, including capillary tube action, electromagnetic power,
and attractive force between molecules or atoms, which are
negligible and less influential in the conventional technique, must
be thoroughly considered when molding a nano-sized structure.
[0051] Thus, the nano-imprinting process according to the present
invention requires the development of material in consideration of
such microphysical phenomena, and requires techniques for managing
fine dust having a size from tens of nanometers to hundreds of
micrometers, easily occurring under general working conditions,
because the mold is manufactured on a nanometer scale. Further,
there is an essential need for a vibration insulation system to
minimize external vibrations during the work. In this way, the
nano-imprinting process according to the present invention is very
different from the conventional technique.
[0052] The nano-imprint mold, having high precision, is separated,
metallized through vapor deposition, and then electroformed, thus
obtaining a plurality of small module master molds.
[0053] In the present invention, vapor deposition is mainly
performed using CVD, but may be carried out through PECVD, APCVD,
or PVD. Before vapor deposition, nano-separation film treatment may
be performed, as necessary. The metallized mold resulting from
vapor deposition is subjected to electroforming, thus obtaining a
plurality of small module master molds (S130).
[0054] For the metallization of the mold, spraying and wet silver
curing are also examples thereof, in addition to vapor deposition,
and any one selected from among them may be applied.
[0055] The nano-pattern of the surface of the object to be
duplicated is subjected to 2D or 3D scanning, thus designing a
predetermined standard pattern and preparing for processing. Such
processing may be performed through etching.
[0056] The edges of the module master molds thus manufactured are
uniformly trimmed, after which predetermined widths of the edges
thereof are subjected to 2D or 3D micro- or nano-processing to
impart the designed standard pattern, and the module master molds
thus processed are arranged, precisely connected through adhesion
or welding, and then electroformed, thereby manufacturing a metal
unit master mold (S140).
[0057] The master mold thus manufactured is in a positive form. In
the case where a negative master mold is required, it may be
ensured by repeating the electroforming. The 2D or 3D processing is
micro- or nano-technology for naturally connecting the edges of
respective module molds having the duplicated nano-imprinted
pattern.
[0058] The electroforming process is a technique for coating the
surface of metal with another metal using the principle of
electrolysis, and is also referred to as an electroplating process.
That is, a plating metal is disposed at the negative electrode, and
an electrodepositing metal is disposed at the positive electrode,
after which the plating metal is placed in the electrolytic
solution containing metal ions to be electrodeposited, and is then
electrolyzed under the flow of current, thereby electrodepositing
the metal ions on the metal surface.
[0059] As a technique corresponding thereto, electroless plating,
chemical plating, and self-catalytic plating are exemplary. In the
electroless plating, a reducing agent such as formaldehyde or
hydrazine supplies electrons for reducing metal ions into metal
molecules in an aqueous solution. This reaction occurs on the
surface of the catalyst, and the plating agent includes copper,
nickel-phosphorus alloys, and nickel-boron alloys. The reducing
agent brings about the reduction of another material as it itself
is oxidized, and examples thereof include hydrogen, carbon, metal
sodium, and sulfite. The electroless plating makes the plating
layer denser and the thickness thereof more uniform, compared to
electroplating, and also, may be advantageously applied to various
patterns including plastic or organic substances, and may thus be
used as an alternative in the present invention.
[0060] Next, using the unit master mold, metal electroforming or
plastic extrusion or injection is performed, thus producing a
duplicate having the nano-pattern texture of the surface or skin of
the selected object (S150). The produced duplicate is further
subjected to vapor deposition or painting for coloring treatment
and coating for physical or chemical protection, and is thereby
completed (S160).
[0061] According to the embodiment of the present invention, in the
production of the duplicate having the same nano-pattern texture as
the surface of the object, when an extrusion process is performed
through casting, the unit master mold having the nano-pattern
surface roughness is pressed on plastic, thus producing the
duplicate having the nano-pattern texture, after which the mold is
separated. The production method according to the present invention
is characterized in that it requires techniques for precise
arrangement, vibration insulation to minimize external vibration,
equilibrium between the nano mold and the plastic and defoaming,
plating, having micro- or nano-precision, and the application of
uniform pressure over a large area, and is thus evidently different
from the conventional technique. The nano-pattern texture of the
surface of the selected object may also be duplicated on metal
through electroforming.
[0062] Referring to FIG. 2, there is illustrated a large-area mold
completed by subjecting the plurality of small module master molds,
in which the front and back surfaces of natural leather, selected
according to the embodiment of the present invention, are
nano-imprinted, to 2D or 3D processing and precise edge processing
to impart the standard pattern, and connecting the module master
molds.
[0063] That is, the front and back surfaces of natural leather,
having a small size, are imprinted through hot embossing using a
thermoplastic polymer film, and are then subjected to 2D or 3D edge
processing to impart the standard pattern set through surface
scanning, thereby completing the mold.
[0064] FIG. 3 is a photograph, magnified 2.times., of the front
surface of natural leather selected for nano-imprinting of the
surface texture according to the embodiment of the present
invention, FIG. 4 is a photograph, magnified 2.times., of the mold
imprinted with the natural leather of FIG. 3, FIG. 5 is a
photograph, magnified 2.times., of the back surface of natural
leather selected for imprinting according to the embodiment of the
present invention, FIG. 6 is a photograph, magnified 2.times., of
the mold imprinted with the natural leather of FIG. 5, and FIG. 7
is a photograph of the state of a final product having the
nano-pattern texture of the surface of the object selected
according to the embodiment of the present invention, duplicated
thereon.
[0065] The nano-pattern texture of the surface of the selected
object according to the present invention may be duplicated on
either metal or plastic. Hence, the technique of the present
invention as above is advantageous because the nano-pattern texture
of the skin or surface of the selected object is nano-imprinted,
thus manufacturing the mold, which is then repeatedly
electroformed, thus duplicating it on metal or plastic.
[0066] The preferred embodiment of the present invention is set
forth for illustration, but is not to be construed to limit the
present invention, and may be variously modified within a range
that does not deviate from the technical spirit of the present
invention. Accordingly, the exemplary embodiments disclosed in the
present invention do not limit the technical spirit of the present
invention but are intended to explain it, and the technical spirit
of the present invention is not limited thereby. The scope of the
present invention should be defined by the accompanying claims, and
all technical variations that fall within the range equivalent
thereto should be regarded as being included in the scope of the
present invention.
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