Method for manufacturing a horology component

Patent metadata

Field	Value
Publication number	US-11803121-B2
Application number	US-201916718578-A
Country	US
Kind code	B2
Filing date	Dec 18, 2019
Priority date	Dec 21, 2018
Publication date	Oct 31, 2023
Grant date	Oct 31, 2023

Abstract

Method for manufacturing a master pattern for a mold for a horology component, wherein the method includes manufacturing a first structure from a first photosensitive resin comprising at least one layer of photosensitive resin comprising a first pattern obtained by polymerizing the first photosensitive resin by irradiation through at least one mask, then developing the first photosensitive resin; and transforming the first structure into a second structure by structuring at least one surface of the first structure by the addition of a second photosensitive resin to the at least one surface.

First claim

The invention claimed is:

1. A method for manufacturing a master pattern for a mold for a horology component, wherein the method comprises:
manufacturing a first structure from a first photosensitive resin comprising at least one layer of photosensitive resin comprising a first pattern obtained by polymerizing the first photosensitive resin by irradiation through at least one mask, then developing the first photosensitive resin, the first structure having opposite main surfaces parallel to a main plane of the at least one layer and a lateral surface extending between the main surfaces; and
transforming the first structure into a second structure by structuring at least one portion of the lateral surface of the first structure by the addition of a second photosensitive resin to the at least one portion of the lateral surface,
wherein the transforming comprises:
(i) applying a layer of the second photosensitive resin on at least part of the at least one portion of the lateral surface of the first structure;
(ii) performing two-photon polymerization on the second photosensitive resin in order to obtain three-dimensional polymerization according to a second pattern, using a photon device which comprises an objective lens which is at least partially immersed in the second resin to direct and focus a beam on voxels that define a shape and/or a geometry of the second pattern; and
(iii) developing to eliminate non-polymerized second photosensitive resin and obtain the second structure formed on the at least one portion of the lateral surface of the first structure and having a shape defined by the first and second patterns.

2. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 1 , wherein the performing of the two-photon polymerization makes it possible to define the second pattern with a three-dimensional resolution equal to 0.001 μm 3 or better and/or with a lateral resolution equal to 0.1 μm or better.

3. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 2 , wherein the first photosensitive resin covers all or part of a substrate, wherein the developing of the first photosensitive resin comprises exposing the first resin, and wherein the exposing of the first resin generates the first structure comprising lateral flanks perpendicular or substantially perpendicular to the substrate and/or a constant cross section parallel or substantially parallel to the substrate.

4. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 3 , wherein the second structure directly forms the master pattern of a mold for a horology component.

5. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 2 , wherein:
the two resins are identical; and/or
both resins are positive or both resins are negative; and/or
the first resin is a negative photosensitive resin which becomes polymerized under action of UV radiation; and/or
the second resin is a liquid or semiliquid resin.

6. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 2 , wherein the second structure directly forms the master pattern of a mold for a horology component.

7. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 1 , wherein:
the two resins are identical; and/or
both resins are positive or both resins are negative; and/or
the first resin is a negative photosensitive resin which becomes polymerized under action of UV radiation; and/or
the second resin is a liquid or semiliquid resin.

8. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 1 , wherein the method further comprises:
using electrodeposition or electroplating to apply to the second structure a layer of metal that at least partially forms the master pattern for the mold for the horology component; and
separating from the second structure the master pattern for the mold for the horology component which is formed by the layer of metal.

9. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 8 , wherein the metal is nickel-based or is a nickel-phosphorus alloy.

10. A method for manufacturing a blank for a mold for a horology component, wherein the method comprises:
manufacturing the master pattern by the method as claimed in claim 1 ,
filling the second structure by pouring a pourable product containing ceramic powder and at least one binder;
consolidating the product into a solid product;
separating from the second structure the blank formed by the solid product; and
debinding the blank obtained in the separating, then densifying the blank by sintering.

11. The method for manufacturing a master pattern for a mold for a horology component as claimed in claim 1 , wherein the second structure directly forms the master pattern of a mold for a horology component.

12. A method for manufacturing a horology component, wherein the method comprises:
manufacturing the master pattern using the method as claimed in claim 1 ,
using the master pattern to manufacture a mold for manufacturing a horology component, and then
using the mold as a manufacturing mold to manufacture the horology component.

13. The method for manufacturing a horology component as claimed in claim 12 , wherein the mold is manufactured from a polymer.

14. The method for manufacturing a horology component as claimed in claim 13 , wherein the using of the master pattern to manufacture the mold comprises:
circumscribing, with an annular element, a volume intended to receive a volume of polymer, to complement the master pattern;
pouring a volume of elastomer into an impression cavity formed by the master pattern completed by the annular element;
polymerizing the volume of elastomer so as to solidify it;
separating the elastomer mold from the master pattern and from the annular element.

15. The method for manufacturing a horology component as claimed in claim 13 , wherein the mold is manufactured from an elastomer.

16. The method for manufacturing a horology component as claimed in claim 15 , wherein the mold is manufactured from polydimethylsiloxane (PDMS) or silicone.

17. The method for manufacturing a horology component as claimed in claim 12 , wherein the mold is manufactured in metal or in metal alloy or in ceramic.

18. The method for manufacturing a horology component as claimed in claim 12 , wherein the manufacturing of the horology component comprises manufacturing the horology component in technical ceramic using the following:
filling the mold by pouring a pourable product containing ceramic powder and at least one binder;
consolidating the product into a solid product;
separating a blank formed by the solid product from the manufacturing mold; and
debinding the blank obtained in the separating, then densifying the blank by sintering.

19. The method for manufacturing a horology component as claimed in claim 12 , wherein the horology component is made of ceramic.

20. The method for manufacturing a horology component as claimed in claim 19 , wherein the horology component is made of technical ceramic.

Assignees

• Rolex Sa

Inventors

• Calame Florian
• Maegli Alexandra
• Multone Xavier

Classifications

• G03F7/2012

  using liquid photohardening compositions, e.g. for the production of reliefs such as flexographic plates or stamps · CPC title

• G03F7/038

  Macromolecular compounds which are rendered insoluble or differentially wettable (G03F7/075 takes precedence; macromolecular azides G03F7/012; macromolecular diazonium compounds G03F7/021) · CPC title

• G03F7/2053

  using a laser (ablative removal B41C) · CPC title

• G03F7/0035

  Multiple processes, e.g. applying a further resist layer on an already in a previously step, processed pattern or textured surface · CPC title

• G03F7/0037

  Production of three-dimensional images · CPC title