Flexible die and method of manufacturing the flexibel die

Abstract

To obtain a push-cutting blade 2, a flexible base 1 and a projection (trapezoid-section projection 21 ) protruding from this base are formed by etching. Then, a lateral surface or surfaces of the projection 21 is cut into a vertical projection 2 b. Lastly, the tip of the vertical projection 2 b is sharpened to give a double (or single) cutting edge 2 a.

1 . A flexible die which comprises a flexible base and a push-cutting blade formed in a predetermined pattern on one surface of the flexible base, characterized in that the push-cutting blade is composed of a vertical projection protruding vertically from the flexible base, and a single cutting edge or a double cutting edge formed by sharpening a tip of the vertical projection.  
     
     
         2 . A method for manufacturing a flexible die which comprises a flexible base and a push-cutting blade formed in a predetermined pattern on one surface of the flexible base, 
 characterized in comprising the steps of: 
 laminating a photoresist uniformly on a surface of a metal plate, and exposing and developing the photoresist layer, thereby to form a resist pattern for the push-cutting blade on the surface of the metal plate;  
 with the use of the resist pattern as a mask, etching the metal plate to a predetermined depth, thereby to form the flexible base and a projection which protrudes from the base;  
 cutting a lateral surface of the projection to shape a vertical projection; and  
 sharpening a tip of the vertical projection to give a single cutting edge or a double cutting edge.  
   
     
     
         3 . A method for manufacturing a flexible die which comprises a flexible base and a push-cutting blade formed in a predetermined pattern on one surface of the flexible base, 
 characterized in comprising the steps of: 
 laminating a photoresist uniformly on a surface of a metal plate, and exposing and developing the photoresist layer, thereby to form a resist pattern for the push-cutting blade on the surface of the metal plate;  
 with the use of the resist pattern as a mask, etching the metal plate to a predetermined depth, thereby to form the flexible base and a projection which protrudes from the base;  
 sharpening a tip of the projection to give a single cutting edge or a double cutting edge; and  
 cutting a lateral surface of the sharpened projection to shape a vertical projection.  
   
     
     
         4 . A method for manufacturing a flexible die which comprises a flexible base and a push-cutting blade formed in a predetermined pattern on one surface of the flexible base, 
 characterized in comprising the steps of: 
 laminating a photoresist uniformly on a surface of a metal plate, and exposing and developing the photoresist layer, thereby to form a resist pattern for the push-cutting blade on the surface of the metal plate;  
 with the use of the resist pattern as a mask, etching the metal plate to a predetermined depth, thereby to form the flexible base and a projection which protrudes from the base;  
 machining a lateral surface of the projection by wire EDM to shape a vertical projection; and  
 sharpening a tip of the vertical projection to give a single cutting edge or a double cutting edge.  
   
     
     
         5 . A method for manufacturing a flexible die which comprises a flexible base and a push-cutting blade formed in a predetermined pattern on one surface of the flexible base, 
 characterized in comprising the steps of: 
 laminating a photoresist uniformly on a surface of a metal plate, and exposing and developing the photoresist layer, thereby to form a resist pattern for the push-cutting blade on the surface of the metal plate;  
 with the use of the resist pattern as a mask, etching the metal plate to a predetermined depth, thereby to form the flexible base and a projection which protrudes from the base;  
 sharpening a tip of the projection to give a single cutting edge or a double cutting edge; and  
 machining a lateral surface of the sharpened projection by wire EDM to shape a vertical projection.