Patent ID: 6764924
Filing Date: 2004-07-20
Classification: B23P,B29C,B29L,B81C

Abstract:
A process for producing a tool insert used in a mold for injection molding a part fabricated of a synthetic material, a metal or a ceramic material and which includes an arrangement of microstructures formed on an outer surface of the part and have a predetermined depth, said process comprising:(a) photo-lithographically masking the front side of a first wafer with a first etching mask which corresponds to an arrangement of microstructures, (b) micro-structuring the first wafer by means of plasma etching the front side of the first wafer to form an arrangement of microstructures which form cavities and whose depth extends over a part of the thickness of the first wafer, (c) removing the first etching mask from the front side of the first wafer, (d) bonding the front side of the first wafer to a carrier substrate to form a master, (e) removing a layer of the first wafer to reveal the microstructures which have not been through-etched and to set the depth of the microstructures, (f) applying an electrically conductive thin layer to the rear side of the first wafer and to the carrier substrate surfaces which can be accessed through the cavities mentioned, (g) electrochemically depositing a metal layer on the rear side of the first wafer and in the cavities which are present therein and are formed by the microstructures, (h) making planar the outer surface of the deposited metal layer, and (i) separating the metal layer from the master, wherein the separated metal layer can be used as a tool insert for injection molding a part.