Matrix and method of producing said matrix
View Patent ↗The invention relates to a matrix suitable for use in the replication of a plastic element having a positive microstructure, comprising a first wear-resistant layer that is supported by a carrier element, wherein the matrix comprises a heating means for supplying electrical heat energy through the wear-resistant layer or carrier element. The invention further relates to a plastic element producing machine and a method for the manufacture of a plastic element having a surface with a positive microstructure.
1. A matrix for use in the replication of a plastic element having a positive microstructure, comprising:
a first wear-resistant layer;
wherein said layer is supported by a carrier element and consists of an electrically conducting or semi-conducting material;
wherein said matrix is in the form of a singular structure mould cavity insert and is connected to a source of electrical heat energy via the first wear-resistant layer or a layer supporting the first wear-resistant layer by a connecting means;
wherein said carrier element acts as a heat insulator; and
wherein said carrier element has a thermal conductivity less than 2 W/m/° K.
2. The matrix of claim 1 , wherein the carrier element has a resistivity of less than 0.3 ohms×mm 2 /m.
3. The matrix of claim 1 , wherein the carrier element has a resistivity of less than 0.03 ohms×mm 2 /m.
4. The matrix of claim 1 , wherein the carrier element is capable of producing heat.
5. The matrix of claim 1 , wherein the electrical heat energy is supplied by applying a voltage to the electrically conducting or semi-conducting material of the first wear-resistant layer.
6. The matrix of claim 1 , wherein said carrier element comprises a polymer material that acts as a heat shield.
7. The matrix of claim 1 , wherein said carrier element comprises a plastic composite.
8. The matrix of claim 1 , wherein said first wear-resistant layer has a thickness ranging from about 1 to about 50 μm.
9. The matrix of claim 1 , wherein said first wear-resistant layer is a metal layer.
10. The matrix of claim 1 , wherein said first wear-resistant layer exposes an inverse microstructure on its surface having a depth variation ranging from about 0.1 to about 1000 μm.
11. The matrix of claim 1 , wherein said carrier element comprises a polymer material that act as the heat insulator.
12. The matrix of claim 1 , wherein said conducting or semi-conducting material has a resistivity of between 0.025 and 0.12 ohms×mm 2 /m.
13. A plastic element-producing machine, comprising:
a matrix, wherein said matrix comprising:
a first wear-resistant layer;
wherein said layer is supported by a carrier element and consists of an electrically conducting or semi-conducting material;
wherein said matrix is in the form of a singular structure mould cavity insert and is connected to a source of electrical heat energy via the first wear-resistant layer or a layer supporting the first wear-resistant layer by a connecting means;
wherein said carrier element acts as a heat insulator;
wherein said machine is a compression moulding, an injection moulding, or an embossing machine; and
wherein said carrier element has a thermal conductivity less than 2 W/m/° K.
14. A method for the manufacture of a plastic element having a surface with a positive microstructure comprising the steps of:
(i) providing a matrix, wherein said matrix comprising:
a first wear-resistant layer;
wherein said layer is supported by a carrier element and consists of an electrically conducting or semi-conducting material;
wherein said matrix is in the form of a singular structure mould cavity insert and is connected to a source of electrical heat energy via the first wear-resistant layer or a layer supporting the first wear-resistant layer by a connecting means;
wherein said carrier element acts as a heat insulator;
wherein said carrier element has a thermal conductivity less than 2 W/m° K; and
(ii) replicating said plastic element on said matrix while supplying heat energy to the electrically conducting or semi-conducting material of the first wear-resistant layer during the filling of the matrix mould cavity with molten plastic.
15. The method of claim 13 , wherein step (ii) is performed in a plastic element-producing machine based on replication of the matrix.
16. The method of claim 14 , where said plastic element-producing machine is a compression moulding, an injection moulding or an embossing machine.
17. The method of claim 14 , wherein said first wear layer is a metal layer.
18. The method of claim 14 , wherein said plastic element is an optical disc.
19. A matrix for use in the replication of a plastic element having a positive microstructure, comprising:
a first wear-resistant layer;
wherein said layer is supported by a carrier element and consists of an electrically conducting or semi-conducting material;
wherein said matrix is in the form of a singular structure mould cavity insert and is connected to a source of electrical heat energy via the first wear-resistant layer or a layer supporting the first wear-resistant layer by a connecting means;
wherein said carrier element acts as a heat insulator; and wherein said carrier element comprises a plastic composite.
20. The matrix of claim 19 , wherein the carrier element has a resistivity of less than 0.3 ohms×mm 2 /m.
21. The matrix of claim 19 , wherein the carrier element has a resistivity of less than 0.03 ohms×mm 2 /m.
22. The matrix of claim 19 , wherein the carrier element is capable of producing heat.
23. The matrix of claim 19 , wherein the electrical heat energy is supplied by applying a voltage to the electrically conducting or semi-conducting material of the first wear-resistant layer.
24. The matrix of claim 19 , wherein said first wear-resistant layer has a thickness ranging from about 1 to about 50 μm.
25. The matrix of claim 19 , wherein said first wear-resistant layer is a metal layer.
26. The matrix of claim 19 , wherein said first wear-resistant layer exposes an inverse microstructure on its surface having a depth variation ranging from about 0.1 to about 1000 μm.
27. The matrix of claim 19 , wherein said conducting or semi-conducting material has a resistivity of between 0.025 and 0.12 ohms×mm 2 /m.
28. A plastic element-producing machine, comprising:
a matrix, wherein said matrix comprising:
a first wear-resistant layer;
wherein said layer is supported by a carrier element and consists of an electrically conducting or semi-conducting material;
wherein said matrix is in the form of a singular structure mould cavity insert and is connected to a source of electrical heat energy via the first wear-resistant layer or a layer supporting the first wear-resistant layer by a connecting means;
wherein said carrier element acts as a heat insulator; and
wherein said machine is a compression moulding, an injection moulding, or an embossing machine; and
wherein said carrier element comprises a plastic composite.
29. A method for the manufacture of a plastic element having a surface with a positive microstructure comprising the steps of:
(i) providing a matrix, wherein said matrix comprising:
a first wear-resistant layer;
wherein said layer is supported by a carrier element and consists of an electrically conducting or semi-conducting material;
wherein said matrix is in the form of a singular structure mould cavity insert and is connected to a source of electrical heat energy via the first wear-resistant layer or a layer supporting the first wear-resistant layer by a connecting means;
wherein said carrier element acts as a heat insulator;
wherein said carrier element comprises a plastic composite; and
(ii) replicating said plastic element on said matrix while supplying heat energy to the electrically conducting or semi-conducting material of the first wear-resistant layer during the filling of the matrix mould cavity with molten plastic.
30. The method of claim 29 , wherein step (ii) is performed in a plastic element-producing machine based on replication of the matrix.
31. The method of claim 30 , where said plastic element-producing machine is a compression moulding, an injection moulding or an embossing machine.
32. The method of claim 30 , wherein said first wear layer is a metal layer.
33. The method of claim 30 , wherein said plastic element is an optical disc.