JP2008081917A - Papermaking mold and molded paper - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provided a papermaking mold suitable for producing a molded paper having a reduced interval between plate-shaped protrusions. <P>SOLUTION: A papermaking mold 10 includes a mold body 10A and a papermaking net 108 arranged in a papermaking portion of the mold body 10A. The papermaking mold 10 includes a column-shaped ridge 106 lying on a base surface 102 of the papermaking portion, and at least two plate-shaped ridges 105 are formed at a predetermined interval at predetermined positions in the longitudinal direction of the column-shaped ridge 106 such that the adjoining inner face portions 105A of the plate-shaped ridges 105 are formed of part of a circular cone or a hyperboloid. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a papermaking mold and a papermaking molded body.

  The applicant has proposed the technique described in Patent Document 1 below as a method for producing a paper-molded article. In this technique, a fiber laminate is made from a raw material slurry containing fiber materials such as inorganic fibers and organic fibers, and a paper-made formed body having a desired forming surface is produced by performing dehydration and dry forming.

1 and the like of Patent Document 1 have a semi-columnar columnar convex portion lying on the base surface portion of the papermaking surface, and a semi-cylindrical plate at a predetermined position in the length direction of the columnar convex portion. A papermaking mold in which two convex portions are formed at a predetermined interval is disclosed.
When using such a papermaking mold to make a papermaking molded body as shown in FIG. 8 of Patent Document 1, generally, after removing the papermaking molded body from the papermaking mold without any trouble, A draft angle is given to the plate-like convex portion on the base surface portion in a planar (two-dimensional) manner with reference to the base surface portion (see FIG. 14, however, the draft angle is emphasized).

  By the way, when it is desired to reduce the interval between the plate-like convex portions of the resulting papermaking body, it is also necessary to reduce the interval between the plate-like convex portions in the papermaking mold. However, if this interval is narrowed, when making a fiber laminate, which is an intermediate of the papermaking molded product, the raw material slurry becomes difficult to enter between the plate-like convex portions in the papermaking mold, and the fibers in that portion In some cases, the thickness of the laminate was thin or papermaking was not possible. For this reason, it has been difficult to produce a paper-molded molded body in which the interval between the plate-like convex portions is tight.

JP-A-2005-290600

  This invention is made | formed in view of the said subject, and aims at providing the papermaking type | mold suitable for manufacture of the papermaking molded object with which the space | interval of plate-shaped convex parts was closed, and its papermaking molded object.

  The present invention is a papermaking mold comprising a mold body and a papermaking net disposed in the papermaking portion of the mold body, and has a columnar convex portion lying on the base surface portion of the papermaking portion, and the columnar convex portion Two or more plate-like convex portions are formed at predetermined intervals in the length direction, and the adjacent inner surface portions of the plate-like convex portions are provided as part of a conical surface or a hyperboloid. By providing the above, the above object is achieved.

  The present invention also provides a paper-molded molded article having a flange portion, which has a columnar convex portion lying on a substrate portion including the flange portion, and a plate-like convex portion at a predetermined position in the length direction of the columnar convex portion. Two or more portions are formed at a predetermined interval, and a papermaking molded body is provided in which adjacent inner surface portions of the plate-like convex portions are provided with a part of a conical surface or a hyperboloid.

  Further, the present invention is a mold having a concave portion that becomes a molding surface of a cast body in which a plurality of plate-like portions are cast at a predetermined interval, and the concave portion is recessed from a base surface portion and spaced in a predetermined direction. A plurality of plate-shaped convex portion forming concave portions arranged side by side, and the adjacent inner surface portions of the plate-shaped convex portion forming concave portions are provided as part of a conical surface or a hyperboloid Is to provide.

  Further, the present invention is a dry mold comprising a pair of female molds and male molds used in the production of the paper-molded molded article of the present invention, and when the female mold and the male mold are brought into contact with each other, The present invention provides a dry mold in which a gap corresponding to the outer shape of the paper-molded molded body to be molded is formed between the molds.

  Further, the present invention is a male mold constituting the dry mold used for the production of the paper-molded molded article of the present invention, and has a columnar convex portion lying on the base surface portion of the molded portion, Two or more plate-like convex portions are formed at predetermined intervals in a predetermined position in the length direction of the columnar convex portion, and adjacent inner surface portions of the plate-like convex portions are provided as part of a conical surface or a hyperboloid. The present invention provides a male mold constituting a dry mold.

  Further, the present invention is a female mold constituting the dry mold used in the production of the paper-molded molded article of the present invention, and is a concave mold in which the outer shape of the resulting paper-molded molded article is directly opposite to the irregularities. The molding part has two or more concave parts corresponding to the plate-like convex parts of the paper-molded molded body at a predetermined interval, and the inner surface part adjacent to the concave parts is a conical surface or a hyperboloid. The female type | mold which comprises the dry shaping | molding die provided in the part is provided.

  The present invention also relates to a dry mold comprising a pair of female molds and male molds used in the production of the mold of the present invention, and when the female mold and the male mold are brought into contact with each other, The present invention provides a dry mold in which a gap corresponding to the outer shape of a mold to be molded is formed.

  Further, the present invention is a male mold constituting the dry mold used for the production of the mold of the present invention, and has a columnar convex portion lying on the base surface portion of the molded portion, the columnar shape Two or more plate-like convex portions are formed at predetermined intervals in the longitudinal direction of the convex portion, and the adjacent inner surface portions of the plate-like convex portions are provided as part of a conical surface or a hyperboloid. A male mold constituting the dry mold is provided.

  Further, the present invention is a female mold that constitutes the dry mold used in the production of the mold of the present invention, and includes a concave molded portion in which the outer shape of the obtained mold is directly opposite to the irregularities, In the molding part, two or more concave portions corresponding to the plate-like convex portions of the mold are formed at a predetermined interval, and adjacent inner surface portions of the concave portions are provided as a part of a conical surface or a hyperboloid. A female mold constituting a dry mold is provided.

  After making a wet fiber laminate from the raw slurry using the papermaking mold of the present invention, the fiber laminate is dried from the papermaking mold and used in the production of the papermaking molded body of the present invention. A method for producing a papermaking molded body is provided in which the fiber laminate is press-molded between the female mold and the male mold constituting the dry mold to produce a papermaking molded body. It is.

  After making a wet fiber laminate from the raw slurry using the papermaking mold of the present invention, the fiber laminate is made from the papermaking mold, and the female constituting the dry mold used for the production of the mold. The present invention provides a mold manufacturing method in which the fiber laminate is press-molded between the female mold and the male mold constituting the dry mold, and the mold is manufactured.

  ADVANTAGE OF THE INVENTION According to this invention, the papermaking molded object with which the space | interval of plate-shaped convex parts was closed, and the papermaking mold | type suitable for the manufacture are provided.

The present invention will be described below based on preferred embodiments with reference to the drawings.
First, a preferred embodiment of the papermaking mold of the present invention will be described.
In the present application, the papermaking molded product refers to a product obtained by dehydrating and drying a fiber laminate in which papermaking raw materials such as fibers are deposited in a papermaking mold.

1 and 2 show an embodiment of the papermaking mold of the present invention.
The papermaking mold 10 includes a papermaking section 100 on the upper surface of the mold body 10A. The papermaking unit 100 is provided with a recess (step) 103 having a base surface part 102 at a position lower than the butting surface 101 of the papermaking mold 10.

The paper making section 100 has a plate-like convex portion 105 and a columnar convex portion 106 as the convex portions 104. In FIG. 1, the cross section of the columnar convex part and the plate-shaped convex part in the length direction is shown in a semicircular shape. Hereinafter, the cross section of each convex part in the length direction will be described as a case where it is mainly semicircular.
The papermaking unit 100 has a columnar convex portion 106 having a semicircular cross section in the length direction lying on the base surface portion 102 and a semicircular cross section in the length direction at a predetermined position in the length direction of the columnar convex portion. Two plate-like convex portions 105 having a shape are provided. The diameter of the plate-like convex portion 105 is set larger than the diameter of the columnar convex portion 106. The plate-like convex portion 105 and the columnar convex portion 106 are provided so that the center of the semicircular cross section is located on the same axis C (see FIG. 2B). Both end portions of the columnar convex portion 106 project outward from the plate surface portion 105 </ b> B outside the plate-shaped convex portion 105. The base surface portion 102 and the convex portion 104 of the papermaking unit 100 are provided with a gas-liquid flow passage 107 that opens on the surface thereof inside the papermaking die 10. A papermaking net 108 is attached to the surface of the papermaking unit 100. As the papermaking net 108, a publicly known one that has been conventionally used for the production of this type of papermaking molded article can be used.

  Adjacent plate surface portions (inner surface portions) 105 </ b> A between the plate-like convex portions 105 are provided on a part of a conical surface having an apex S on the axis C of the circular cross section of the columnar convex portion 106 on the base surface portion 102. ing. Here, in this specification, a conical surface is a straight line (for example, a straight line connecting point R and vertex S in FIG. 2) that intersects with another straight line (for example, axis C in FIG. 2). R is a curved surface drawn when an arbitrary point on an outer peripheral edge 105C described later is rotated. The part of the conical surface is a portion of the conical surface excluding a portion hidden by the columnar convex portion (in FIG. 2A, a dotted line portion is shown in a straight line connecting the point R and the vertex S). That means. For example, in FIG. 2A, a portion surrounded by R-R1-R2-R3 is referred to, and in FIG. 2B, a portion surrounded by R-R3-R3-R is referred to. It should be noted that the angle at which the straight lines intersect (hereinafter also referred to as the conical surface gradient α) when the other straight line intersecting with the straight line is made within a range that does not impair the effects of the present invention. However, the plate-like convex portion may have a non-semicircular shape when the gradient α is changed. The conical surface as the plate surface portion 105A is preferably provided so that the vertex S is located on the axial center C of the circular cross section of the plate-like convex portion 105 and the columnar convex portion 106, but the effect obtained by the present invention is affected. The apex may be displaced from the axis C and the base surface portion 102 within a range that does not extend. The gradient α of the conical surface as the plate surface portion 105A is the difference between the outer peripheral edge 105C and the inner peripheral edge 105D of the plate surface portion 105A of the plate-like convex portion 105 (the diameter of the semicircular cross section of the plate-like convex portion and the semicircle of the columnar convex portion). It is determined by the difference in diameter of the cross section) and the distance d between the outer peripheral edge and the inner peripheral edge (see FIG. 2B). The gradient α is preferably 0.1 to 10 degrees, more preferably 0.5 to 5 degrees, and more preferably 1 to 3 degrees. When the gradient α of the conical surface is within such a range, it can be easily removed from the production mold without damaging the fiber laminate, and the interval between the plate-like portions can be narrowed. The distance D between the plate surface portions 105A is preferably 1 to 50 mm from the viewpoint of ease of papermaking and unnecessary papermaking materials.

  In the papermaking mold 10 having the above-described configuration, the plate surface portion 105A of the plate-like portion convex portion 105 is provided with the conical surface as described above, so that the papermaking raw material can easily reach the papermaking net 108 between the plate-like convex portions 105. . Therefore, even if the space | interval of plate-shaped convex parts is closed, the papermaking molded object without a crack can be produced.

Next, an embodiment of a dry mold used for manufacturing the papermaking molded body together with the papermaking mold 10 will be described.
As shown in FIG. 3, the dry mold of this embodiment includes a female mold 20 and a male mold 30 for dry molding. When the female mold 20 and the male mold 30 are brought into contact with each other, a gap (clearance) corresponding to the outer shape of the papermaking molded body 40A to be molded is formed between these molds.

  As shown in FIGS. 3 and 4, the female mold 20 includes a concave molded portion 200 in which the outer shape of the resulting papermaking molded body 40 </ b> A is reversed as it is. The surface of the molded part 200 is coated with a fluororesin. The molding part 200 has a stepped part 202 that is recessed from the abutting surface 201 and into which the flange part 42 of the papermaking molded body 40A is accommodated. Further, the molding part 200 has a concave part 204 that is recessed from the base surface part 203 of the step part 202 and corresponds to the plate-like convex part of the papermaking molded body 40A, and a concave part 205 that corresponds to the columnar convex part. The concave portion 204 corresponding to the plate-like convex portion and the concave portion 205 corresponding to the columnar convex portion are provided such that the center of the semicircular cross section is located on the same axis C (see FIG. 4B). And the space formation part mentioned later is formed of these step part 202, the recessed part 204 corresponding to a plate-shaped convex part, and the recessed part 205 corresponding to a columnar convex part. The female mold 20 is provided with a gas-liquid flow passage 206 that opens on the surface of the molding part 200 inside the female mold 20.

  Adjacent plate surface portions (inner surface portions) 204A of the concave portions 204 corresponding to the plate-shaped convex portions are provided at a part of the conical surface. The conical surface as the inner surface portion 204A is preferably provided so that the apex S is positioned at the axis C of the outer peripheral edge 204C and the inner peripheral edge 204D of the plate-shaped convex portion forming concave portion 204, but the effect obtained by the present invention. The vertex may be displaced from the axis C and the base surface portion 203 within a range that does not affect the above.

  As shown in FIGS. 3 and 5, the male mold 30 is provided with a molding part 300 having the same outer shape as the papermaking part (excluding the papermaking net) 100 of the papermaking mold 10 described above. This is because the wet fiber laminate produced by the papermaking mold 10 is attached to the male mold 30 and dried. The surface of the molded part 300 is coated with a fluororesin. The molding part 300 has a base surface part 301 and a convex part 302 protruding from the base surface part 301. The convex portion 302 further has a columnar convex portion 304 having a semicircular cross section lying on the base surface portion 301 and a plate-shaped convex portion having a semicircular cross section in a predetermined position in the length direction of the columnar convex portion. Two parts 303 are provided. The diameter of the plate-like convex portion 303 is set larger than the diameter of the columnar convex portion 304. The plate-like convex portion 303 and the columnar convex portion 304 are provided so that the centers of the semicircular cross sections are located on the same axis. Both end portions of the columnar convex portion 304 protrude outward from the plate surface portion 303B outside the plate-shaped convex portion 303. A gas-liquid flow passage 305 that opens on the surface of the base surface portion 301 and the convex portion 302 of the molding portion 300 is provided inside the male mold 30.

  Adjacent plate surface portions (inner surface portions) 303A between the plate-like convex portions 303 are provided on a part of a conical surface having a vertex S on the axis C of the circular cross section of the plate-like convex portion 303 on the base surface portion 301. It has been. The conical surface as the plate-like convex portion 303 is preferably provided so that the vertex S is positioned on the axial center of the circular cross section of the plate-like convex portion 303 and the columnar convex portion 304, but it affects the effect obtained by the present invention. The apex may deviate from the axis C and the base surface portion 301 within a range that does not affect. The gradient α of the conical surface as the plate surface portion 303A is the difference between the outer peripheral edge 303C and the inner peripheral edge 303D of the plate surface portion 303A of the plate-like convex portion 303 (the diameter of the semicircular cross section of the plate-like convex portion and the semicircle of the columnar convex portion). It is determined by the difference in diameter of the cross section) and the distance d between the outer and inner peripheral edges (see FIG. 5B). The gradient α is preferably 0.1 to 10 degrees, more preferably 0.5 to 5 degrees, and more preferably 1 to 3 degrees. When the gradient α of the conical surface is within such a range, it can be easily removed from the production mold without damaging the fiber laminate, and the interval between the plate-like portions can be narrowed. The distance D between the plate surface portions 303A is preferably 1 to 50 mm from the viewpoint that the papermaking compact can be made compact.

  In the dry mold having the above-described configuration, the plate surface portion 303A of the male plate-like convex portion 303 is provided as a part of the conical surface as described above. Can be done without any problem. In addition, a mold suitable for producing a cast body in which the intervals between plate-like parts described later are packed can be produced with a paper-made molded body having a thin wall and no cracks.

  Next, the papermaking molded body of the present invention will be described as a preferred embodiment thereof with reference to FIGS. 6 and 7 based on the papermaking molded body produced by the papermaking mold and the dry molding mold of the above embodiment.

40A and 40B shown in FIG. 6 are appearances of the papermaking compact 40, and 40B is an appearance when the papermaking compact 40A is turned upside down. Only 40A will be described below.
Since the papermaking compact 40A is molded by the dry mold (female mold 20, male mold 30), it has the same surface shape as the molded part of the dry mold. The papermaking molded body 40 </ b> A has a plate-like convex portion 411 and a columnar convex portion 412 as the convex portion 41. In FIG. 6, the outer shapes of the columnar convex portions 412 and the plate-shaped convex portions 411 are semi-cylindrical (the cross-sectional shape in the length direction of the plate-shaped convex portions 411 and the cross-sectional shape in the length direction of the columnar convex portions 412 are semicircular arcs. ). Hereinafter, the outer shape of each convex portion will be described as a case of a semi-cylindrical shape.
The papermaking molded body 40 has a columnar convex portion 412 lying on the substrate portion 420 including the flange portion 42, and the plate-shaped convex portions 411 are arranged at predetermined intervals in the longitudinal direction of the columnar convex portion 2. One is formed. The diameter of the plate-like convex portion 411 is set larger than the diameter of the columnar convex portion 412. The plate-like convex portion 411 and the columnar convex portion 412 are provided so that the centers of the semicircular cross sections are located on the same axis C ′ (see FIG. 7B). Both end portions of the columnar convex portion 412 protrude outward from the plate surface portion 411B outside the plate-shaped convex portion 411.

  Adjacent plate surface portions (inner surface portions) 411A between the plate-like convex portions 411 are part of a conical surface having a vertex S ′ on the axis C ′ of the circular cross section of the columnar convex portion 412 on the base surface portion 421. Is provided. The conical surface as the plate surface portion 411A is preferably provided so that the vertex S ′ is positioned on the axial center of the circular cross section of the plate-like convex portion 411 and the columnar convex portion 412, but the effect obtained by the present invention is affected. The apex may deviate from the axis C ′ and the base surface portion 421 within a range that does not extend. The gradient β of the conical surface as the plate surface portion 411A is the difference in diameter between the inner surface outer peripheral edge 411′C and the inner surface inner periphery 411′D of the plate surface portion 411A of the plate-shaped convex portion 411 (the inner diameter of the semicircular cross section of the plate-shaped convex portion). And the distance d ′ between the outer peripheral edge of the inner surface and the inner peripheral edge of the inner surface (see FIG. 7B). The gradient β is preferably 0.1 to 10 degrees, more preferably 0.5 to 5 degrees, and more preferably 1 to 3 degrees. When the slope β of the conical surface is within such a range, the fiber laminate can be easily removed from the production mold without damaging the fiber laminate, and the interval between the plate-like portions can be narrowed. The inner surface distance D ′ of the plate surface portion 411 </ b> A is preferably 1 to 50 mm in terms of ease of papermaking and no need for extra papermaking materials. Here, the inner surface refers to a surface I in which the obtained papermaking molded body 40A is in contact with the mold body 10A of the papermaking mold 10.

  The total thickness of the papermaking compact 40A can be set as appropriate, but is preferably 0.5 to 5 mm, more preferably 1 to 2 mm in view of ensuring the strength of the papermaking compact, ensuring air permeability, and suppressing manufacturing costs. preferable.

  The papermaking compact can be used without particular limitation as long as it is a raw material generally used for papermaking. For example, organic fibers, inorganic fibers and the like described in Patent Document 1 can be used as a raw material for the papermaking molded body.

  In addition, as described in Patent Document 1, in the case of using the paper-molded article as a part for casting production with heat resistance, inorganic powder, thermosetting resin, etc. are used in addition to organic fiber and inorganic fiber. Can be used as a raw material. In addition, as an example in which the papermaking molded body is used as a casting production part, Japanese Patent Application Laid-Open No. 2004-195547 of the applicant of the present invention is disclosed.

Next, an apparatus for manufacturing the papermaking compact 40A will be described.
As shown in FIG. 8, the manufacturing apparatus 1 for the papermaking molded body 40 </ b> A includes a raw material supply unit 2, a papermaking unit 3, and a dry molding unit 5.

  The raw material supply means 2 includes an injection frame 210, a vertical movement mechanism 21 that moves the injection frame 210 up and down, and a slurry supply pipe 22 that supplies the raw material slurry into the injection frame 210. A valve 23 is provided in the slurry supply pipe 22.

  The papermaking means 3 includes a papermaking mold 10. A discharge pipe 11 communicating with the suction pump 12 is connected to the gas-liquid flow passage 107 provided in the papermaking unit 100 of the papermaking mold 10. A valve 13 is disposed in the discharge pipe 11.

  The dry molding means 5 includes a female mold 20 for dry molding, a vertical movement mechanism 51 that moves the female mold 20 up and down, and a male mold 30 for dry molding. When the female mold 20 and the male mold 30 are brought into contact with each other, a gap (clearance) corresponding to the outer shape of the papermaking molded body 40A to be molded is formed between these molds.

  The female mold 20 moves up and down by a vertical movement mechanism 51. A flow pipe 52 that leads to a suction pump and a compressor (both not shown) is connected to the gas-liquid flow passage 206 (see FIG. 3) that opens on the surface of the molding portion of the female mold 20. A valve 53 is disposed in the flow pipe 52. The female mold 20 includes a heater (heating means) 54 that heats the molding part 200.

  A discharge pipe 31 communicating with the suction pump 32 is connected to the gas-liquid flow passage 305 (see FIG. 3) that opens on the surface of the molding part 300 of the male mold 30. A valve 33 is disposed in the discharge pipe 31. A concave portion may be formed on the surface of the papermaking molded body 40A at a portion corresponding to the opening of the gas-liquid flow passage 305. When there is a problem in the appearance of the papermaking molded body, the gas-liquid flow passage 305 is There is no need. Although not shown in the drawing, a heater or the like (heating means) for heating the molding unit 300 is disposed inside the molding unit 300.

  The manufacturing apparatus 1 includes moving means (not shown) for moving the papermaking mold 10 and the male mold 30 to predetermined positions along the guide 60 shown in FIG. Further, the manufacturing apparatus 1 includes control means (not shown) including a sequencer that is connected to each of the above-described means and operates each of the means according to a procedure that will be described later.

Next, the manufacturing method of the papermaking molded object 40A using the said manufacturing apparatus 1 is demonstrated, referring drawings.
In the manufacturing method of the papermaking molded body according to the present embodiment, a wet fiber laminate is made from the raw material slurry containing each of the components constituting the papermaking molded body, and then the fiber laminate is changed from the papermaking mold 10 to the female mold 20. Then, the fiber laminate is press-molded between the female mold 20 and the male mold 30 to produce the papermaking molded body 40A.

  In this embodiment, first, raw materials necessary for papermaking such as organic fibers are dispersed in a dispersion medium to prepare a raw material slurry. As the raw material slurry, one prepared so as to be compatible with the papermaking molded article to be manufactured is used. Examples of the dispersion medium include water, white water, solvents such as ethanol and methanol, and mixed systems thereof. Water is particularly preferable from the viewpoints of stability of papermaking and dehydration molding, stability of the quality of the molded body, cost, and ease of handling.

  Other ingredients such as a paper strength reinforcing material such as polyvinyl alcohol, carboxymethyl cellulose (CMC), and polyamidoamine epichlorohydrin resin, an aggregating agent, and a coloring agent may be added to the raw material slurry in an appropriate ratio.

  In the paper making process of the fiber laminate 14 </ b> A, as shown in FIG. 9, the injection frame 210 is lowered by the vertical movement mechanism 21, the valve 23 is opened, and the slurry is supplied into the injection frame 210 through the slurry supply pipe 22. When the supply amount of the slurry reaches a predetermined amount, the valve 23 is closed and the supply of the slurry is stopped. Then, the valve 13 is opened, and the liquid component of the slurry is sucked by the suction pump 12 through the gas-liquid flow passage 107 and the discharge pipe 11, and the solid component is deposited on the surface of the papermaking net 108 and is wet. A body 14A is formed. The liquid content in the fiber laminate 14A is such that the handleability of the fiber laminate 14A, the deformation of the fiber laminate 14A due to the flow of fibers when the fiber laminate 14A is pressed between the female mold 20 and the male mold 30 are pressed. In consideration of the above, the liquid content is preferably 50 to 200 parts by mass, and more preferably 70 to 100 parts by mass with respect to 100 parts by mass of the solid content in the fiber laminate 14A. The liquid content is adjusted by suction of the liquid component through the suction pump 12, and the suction is stopped so as to reach a predetermined liquid content.

  When the paper making of the fiber laminate 14A is completed, as shown in FIG. 10, the injection frame 210 is pulled up by the vertical movement mechanism 21, and the paper making mold 10 is moved along the guide 60 and below the female mold 20 by the moving means. It is.

  Next, the female mold 20 is lowered by the vertical movement mechanism 51 and is brought into contact with the papermaking mold 10.

  Furthermore, the fiber laminate 14A is adsorbed to the molding part 200 side through the flow pipe 52 in the female die 20, and the fiber laminate 14A is removed from the papermaking die 10.

  Next, as shown in FIG. 11, after the male mold 30 is returned below the female mold 20 along the guide 60 by the moving means, the female mold 20 is lowered by the vertical movement mechanism 51. Then, the fiber laminate 14A is pressed against the male mold 30 heated to a predetermined temperature, and the male and female molds are press-molded to obtain a dry papermaking molded body 40A.

  The mold temperatures of the female mold 20 and the male mold 30 are appropriately set according to the papermaking molded body 40A to be manufactured. However, when considering prevention of scorching of the fiber laminate 14A, etc., 100 to 250 ° C. is preferable, and 120 to 200 ° C is more preferred. The pressure of press molding is appropriately determined depending on the type, strength, and the like of the material constituting the papermaking compact 40A.

  During dry molding, the valve 33 is open, and the moisture in the fiber laminate 14A is sucked by the suction pump 32 via the gas-liquid flow passage 305 (see FIG. 3) and the discharge pipe 31, and discharged to the outside. . On the other hand, the injection frame 210 is lowered by the vertical movement mechanism 21, and the papermaking portion 100 of the papermaking mold 10 is included in the injection frame 210 again. Then, the fiber laminate is newly made in the same manner as in the paper making step.

  When the dry molding step is completed, the suction from the flow pipe 52 is switched to the air injection by the compressor, and the female mold 20 is pulled up by the vertical movement mechanism 51 as shown in FIG. Then, after the suction by the suction pump 32 is stopped, the papermaking molded body 40A remaining on the male mold 30 side is removed from the male mold 30 to complete the production of the papermaking molded body 40A. Moreover, the injection frame 210 is pulled up by the vertical movement mechanism 21, and the new fiber laminated body 14A which finished the papermaking process is moved to a heating process after that. In the manufacturing method of the present embodiment, such paper making and dry forming steps are repeated.

  As described above, by using inorganic powder, thermosetting resin or the like in addition to organic fiber and inorganic fiber as the raw material of the paper-molded molded article, heat resistance can be imparted and used as a part for casting production.

Hereinafter, the case where it is used as a casting mold as an example of a casting production part will be described based on the preferred embodiment with reference to the drawings.
First, the composite mold of the present invention will be described based on its preferred embodiment.
The composite mold according to the present embodiment includes a columnar shaft portion and a plurality of disk-shaped plate portions cast integrally with the shaft portion at a predetermined interval along the axis of the shaft portion. Used for casting of existing castings. In the cast body to be cast, the plate surface of the plate-like portion is provided as a part of a conical surface.

  As shown in FIG. 13, the composite mold 130 of the present embodiment is configured by combining a pair of molds 130A and 130B. Each mold is made of a paper-molded article imparted with the heat resistance described above. Since the molds 130A and 130B have the same configuration, the mold 130A will be described below.

  As shown in FIG. 14, the mold 130 </ b> A includes a recess 131 </ b> A that becomes a molding surface of the cast body. The concave portion 131A is provided so as to connect the plate-like convex portion forming concave portion 1311 that is recessed from the base surface portion 1321 of the flange portion 132A and arranged in parallel at a predetermined interval in the predetermined direction, and each plate-like convex portion forming concave portion 1311. The columnar convex portion-forming concave portion 1312 is provided. The concave portion 1312 is provided shallower than the plate-shaped convex portion forming concave portion 1311. The vertical cross-sectional contours of the inner surfaces of the plate-like convex portion forming concave portion 1311 and the columnar convex portion forming concave portion 1312 are set to a semicircular shape having the same axis C ′ (see FIG. 14B). Both end portions of the concave portion 1312 project outward from the plate-shaped convex portion forming concave portion 1311. The base surface portion 1321 becomes a butt surface when combined with the mold 130B.

Adjacent inner surface portions 1311 </ b> A of the plate-shaped convex portion forming concave portions 1311 are provided by a part of the conical surface. Here, the conical surface refers to a curved surface drawn when one straight line intersecting with a straight line is made around the same straight line as in the paper-molded molded body described above. It should be noted that the angle at which the straight lines intersect (hereinafter also referred to as the conical surface gradient β) when the other straight line intersecting the straight line is made within a range that does not impair the effect of the present invention. However, even if it is not constant, it may be changed during one rotation (when the gradient β is changed, the vertical cross-sectional contour of the inner surface of the plate-like convex portion forming concave portion 1311 becomes a non-semicircular shape). The conical surface as the inner surface portion 1311A is preferably provided so that the vertex S ′ is located at the axial center C ′ of the outer peripheral edge 1311C and the inner peripheral edge 1311D of the plate-like convex portion forming concave portion 1311. The apex may deviate from the axial center C ′ and the base surface portion 1321 within a range that does not affect the obtained effect.

  The gradient β of the conical surface as the inner surface portion 1311A is the difference in diameter between the outer peripheral edge 1311C and the inner peripheral edge 1311D of the plate-like convex forming recess 1311 and the distance d ′ between the outer peripheral edge 1311C and the inner peripheral edge 1311D (FIG. 14B). )). The gradient β of the conical surface as the inner surface portion 1311A is preferably 0.1 to 10 degrees, more preferably 0.5 to 5 degrees, and further preferably 1 to 3 degrees. When the gradient β of the conical surface is within such a range, even when the interval between the plate-like portions of the cast body is narrowed, the fiber laminate that becomes the intermediate body of the mold when the mold is molded is removed from the papermaking mold described later. Can be manufactured without damaging when removed.

  The gap D 'between the inner surface portions 1311A is preferably 1 to 50 mm from the viewpoint of ease of papermaking of the fiber laminate and the suppression of excess papermaking materials. Here, the interval between the inner surface portions 1311A refers to the length of the columnar convex portion forming concave portions 1312 provided so as to connect the plate-shaped convex portion forming concave portions 1311.

  The mold 130A preferably has a surface roughness Ra of 20 μm or less, and more preferably 10 μm or less. Here, the surface roughness Ra is measured by Surtronic 10 (manufactured by Rank Taylor Hobson) or the like.

  The total thickness of the mold 130A can be set as appropriate, but it is preferably 0.5 to 5 mm, more preferably 1 to 2 mm in view of ensuring the strength as a mold, ensuring air permeability, suppressing manufacturing costs, and the like.

  The mold 130A is inorganic powder / inorganic fiber / organic fiber / thermosetting resin / thermal expansion relative to the total mass of the inorganic powder, inorganic fiber, organic fiber, thermosetting resin (solid content), and thermally expandable particles. Particles = 70 to 80% / 2 to 8% / 0 to 10% / 8 to 16% / 0.5 to 10% (mass ratio), preferably 70 to 80% / 2 to 6% / 0 to 6% / 10-14% / 2-8% (mass ratio) is more preferable. However, the total of inorganic powder, inorganic fiber, organic fiber, thermosetting resin, and thermally expandable particles is 100% by mass. When the blending ratio of the inorganic powder is within such a range, the shape retention at the time of casting and the surface property of the molded body as a mold are good, and the mold release property after molding is also suitable. When the blending ratio of the inorganic fibers is within such a range, the moldability and shape retention during casting are good. If the blending ratio of the organic fibers is within such a range, the moldability is good. Also, the amount of gas generated by the burning of organic fibers during casting and the amount of organic fibers are better in order to suppress blowing out to the flame from the frying, and may not be included in some cases. When the blending ratio of the thermosetting resin and the thermally expandable particles is within such a range, the moldability of the molded body, the shape retention after casting, and the surface smoothness are good. Further, when the blending ratio of the thermally expandable particles is within such a range, the molding accuracy becomes good.

  Examples of the inorganic powder include graphite such as scaly graphite and earthy graphite, obsidian, and mullite. These inorganic powders can be used alone or in combination of two or more. From the viewpoints of formability and cost, it is preferable to use graphite, particularly scaly graphite.

  The inorganic fiber mainly forms a skeleton of a molded body and maintains its shape without being burned by the heat of molten metal during casting. Examples of the inorganic fibers include artificial mineral fibers such as carbon fibers and rock wool, ceramic fibers, and natural mineral fibers, which can be used alone or in combination of two or more. Among these, it is preferable to use pitch-based or polyacrylonitrile (PAN) -based carbon fibers having high strength even at high temperatures from the viewpoint of effectively suppressing shrinkage due to carbonization of the thermosetting resin, and in particular, PAN-based carbon. Fiber is preferred.

  The inorganic fibers preferably have an average fiber length of 0.5 to 15 mm, particularly 3 to 8 mm, from the viewpoints of dewaterability when the fiber laminate is made and dehydrated, moldability of the fiber molded body, and uniformity. .

  Examples of the organic fiber include paper fiber (pulp fiber), fibrillated synthetic fiber, and regenerated fiber (for example, rayon fiber). The organic fibers can be used alone or in combination of two or more. Paper fiber is preferable from the viewpoints of moldability, strength after drying, and cost.

  Examples of the paper fiber include wood pulp, cotton pulp, linter pulp, bamboo straw and other non-wood pulp. As the paper fiber, these virgin pulp or waste paper pulp can be used alone or in combination of two or more. The paper fiber is particularly preferably used paper pulp from the viewpoints of easy availability, environmental protection, and reduction of manufacturing costs.

  The organic fiber preferably has an average fiber length of 0.8 to 2.0 mm, particularly 0.9 to 1.8 mm in consideration of moldability, surface smoothness, and impact resistance of the molded body.

  The thermosetting resin is a component necessary for maintaining the normal temperature strength and hot strength of the molded body, improving the surface property of the molded body, and improving the surface roughness of the casting. Examples of the thermosetting resin include a phenol resin, an epoxy resin, and a furan resin. Among these, in particular, there is little generation of combustible gas, there is a combustion suppression effect, the residual carbon ratio after pyrolysis (carbonization) is as high as 25% or more, and a good cast skin can be obtained by forming a carbonized film. It is preferable to use a phenol resin from the point which can be performed. As the phenol resin, a novolak phenol resin that requires a curing agent or a resol type phenol resin that does not require a curing agent is used. When a novolac phenol resin is used, a curing agent is required. Since the curing agent is easily soluble in water, it is preferably applied to the surface of the molded body after dehydration. It is preferable to use hexamethylenetetramine or the like as the curing agent. The thermosetting resins can be used alone or in combination of two or more.

  The mold 130A includes, as the thermally expandable particles, thermally expandable particles having an average diameter of preferably 5 to 80 μm, more preferably 25 to 50 μm. When the diameter of the thermally expandable particles is within such a range, the effect of addition can be sufficiently obtained while suppressing adverse effects on the molding accuracy due to expansion.

  The heat-expandable particles are preferably microcapsules in which an expansion agent that evaporates and encapsulates in the shell wall of a thermoplastic resin. When the microcapsules are heated at 80 to 200 ° C., the diameter is preferably 3 to 5 times and the volume is preferably 50 to 100 times, and the average particle size is 5 to 60 μm, particularly 20 to 50 μm. Particles are preferred.

  Examples of the thermoplastic resin constituting the shell wall of the microcapsule include polystyrene, polyethylene, polypropylene, polyacrylonitrile, acrylonitrile-vinylidene chloride copolymer, ethylene-vinyl acetate copolymer, or combinations thereof. Examples of the expanding agent contained in the shell wall include low-boiling organic solvents such as propane, butane, pentane, isobutane, and petroleum ether.

  In addition to the components described above, other components such as polyvinyl alcohol, carboxymethyl cellulose (CMC), a paper strength enhancer such as a polyamidoamine epichlorohydrin resin, a flocculant, and a colorant may be added to the mold 130A at an appropriate ratio. it can.

  The mold 130A preferably has a combustion gas generation amount per unit mass of the part of 250 cc / g or less, and more preferably 200 cc / g or less. The combustion gas generation amount is measured by a combustion gas generation amount measuring device (measuring instrument name: No.682 GAS PRESSURETESTER HARRY W.DIETERT CO.). The lower the amount of combustion gas generated, the better, but the lower limit is practically about 0.1 to 1 cc / g.

  The mold 130A has a moisture content (mass moisture content) in a state before being used for casting of 20% or less, more preferably 10% or less from the viewpoint of suppressing generation of combustion gas accompanying thermal decomposition of the thermosetting resin as much as possible. preferable.

  Next, the mold production mold (papermaking mold and dry mold) of the present invention will be described as a preferred embodiment based on the mold production mold of the above embodiment. In the following, the manufacturing mold of the mold 130A will be described for convenience, and the description of the manufacturing mold of the mold 130B will be omitted.

  The mold 130A is manufactured in the same manner as the papermaking mold of the above-described embodiment (FIG. 1 etc.), and the functions of the papermaking mold are matched with the molds 130A and 130B as described below to form a main mold. In addition, a papermaking mold having a function capable of sharpening each corner portion 133 (see FIG. 13, only 133A) is used so that a gap is not generated in the abutting surface. The papermaking mold will be described below.

  15 and 16 show an embodiment of the papermaking mold used for manufacturing the mold 130. FIG. As shown in FIG. 15A, the papermaking mold 150 includes a papermaking portion 1500 corresponding to the recess 131A that is the molding surface of the mold 130A and the base surface portion 1321 (see FIG. 13) of the flange portion 132A that is the butting surface. Yes.

  The papermaking unit 1500 is provided with a recess (step part) 1503 having a base surface part 1502 at a position lower than the butting surface 1501 of the papermaking mold 150. The base surface portion 1502 of the recess 1503 is provided corresponding to the base surface portion 1321 (see FIG. 13) of the flange portion 132A of the mold 130A.

  The papermaking portion 1500 has a convex portion 1504 corresponding to the concave portion 131 of the mold 130A. The papermaking portion 1500 protrudes from the base surface portion 1502 and has a semicircular cross-section provided so as to connect the plate-like convex portion 1505 having a semicircular cross-section arranged in parallel in a predetermined direction at a predetermined interval. The columnar convex portion 1506 is provided. The plate-like convex portion 1505 and the columnar convex portion 1506 are provided so that the centers of the semicircular cross sections are located on the same axis C (see FIG. 16B). Both end portions of the columnar convex portion 1506 protrude outward from the plate surface portion 1505B outside the plate-shaped convex portion 1505. The base surface portion 1502 and the convex portion 1504 of the papermaking portion 1500 are provided with a gas-liquid flow passage 1507 opened in the surface thereof inside the papermaking die 150. A papermaking net 1508 is attached to the surface of the papermaking unit 1500. As the papermaking net 1508, a publicly known one that has been conventionally used in the production of this type of papermaking compact can be used.

  The depth of the recess 1503 is such that when the paper laminate 150 and a female die 170 described later are combined and the fiber laminate is demolded, the base of the flange portion of the fiber laminate is bent to form a thick portion. The depth is set. The depth of the recess 1503 (depth from the abutting surface 1501) is suitably 1 to 20 mm, and more preferably 3 to 8 mm.

  Adjacent plate surface portions (inner surface portions) 1505A of the plate-shaped convex portions 1505 are provided on a part of a conical surface having a vertex S ′ on the axis C of the circular cross section of the columnar convex portion 1506 on the base surface portion 1502. It has been. The conical surface as the plate surface portion 1505A is preferably provided so that the vertex S ′ is positioned on the axis C of the circular cross section of the plate-like convex portion 1505 and the columnar convex portion 1506, but it affects the effect obtained by the present invention. The apex may deviate from the axis C and the base surface part 1502 in a range that does not affect the above. The gradient α of the conical surface as the plate surface portion 1505A is a difference in diameter between the outer peripheral edge 1505C and the inner peripheral edge 1505D of the plate surface portion 1505A of the plate-like convex portion 1505 (the diameter of the semicircular cross section of the plate-like convex portion and the semicircle of the columnar convex portion). It is determined by the difference in diameter of the cross section) and the distance d between the outer peripheral edge and the inner peripheral edge (see FIG. 16B). The gradient α is preferably 0.1 to 10 degrees, more preferably 0.5 to 5 degrees, and more preferably 1 to 3 degrees. When the gradient α of the conical surface is within such a range, it can be easily removed from the production mold without damaging the fiber laminate, and the interval between the plate-like portions can be narrowed. The distance D 'between the plate-like portions 1505A is preferably 1 to 50 mm from the viewpoint of ease of papermaking and unnecessary papermaking materials.

  In the papermaking mold 150 having the above-described configuration, the plate surface portion 1505A of the plate-like portion convex portion 1505 is provided with the conical surface as described above, so that the papermaking raw material can easily reach the papermaking net 1508 between the plate-like convex portions 1505. . Therefore, it is possible to produce a mold suitable for producing a cast body in which the intervals between the plate-like portions are filled with a paper-made molded body that is thin and has no cracks.

  Next, an embodiment of a dry mold used in the manufacture of the papermaking molded body together with the papermaking mold 150 will be described.

  The dry mold of this embodiment has the same configuration as the above-described dry mold (FIG. 3 and the like), and a gap is formed between the butted surfaces when a mold 130A and a mold 130B as will be described later are butted. In order to prevent the occurrence of the problem, a dry mold having a function capable of sharpening the corners 133A and 133B of each other is used. Hereinafter, an embodiment of the dry mold will be described.

  As shown in FIG. 17, the dry mold of this embodiment includes a female mold 170 and a male mold 180 for dry molding. When the female mold 170 and the male mold 180 are brought into contact with each other, a gap (clearance) corresponding to the outer shape of the mold 130A to be molded is formed between these molds.

  As shown in FIGS. 17 and 18, the female mold 170 includes a concave molding portion 1700 in which the outer shape of the obtained mold 130 </ b> A is directly reversed. The surface of the molded part 1700 is coated with a fluororesin. The forming part 1700 has a stepped part 1702 that is recessed from the abutting surface 1701 and into which the flange part 132 of the mold 130A can be accommodated. Further, the molding portion 1700 includes a plate-shaped convex portion forming concave portion 1704 having a semicircular cross section that is recessed from the base surface portion 1703 of the stepped portion 1702 and arranged in parallel in a predetermined direction, and each plate-shaped convex portion is formed. And a columnar convex forming concave portion 1705 having a semicircular cross section provided so as to connect the concave portion 1704 for use. The plate-like convex portion forming concave portion 1704 and the columnar convex portion forming concave portion 1705 are provided such that the centers of the semicircular cross sections are located on the same axis C (see FIG. 18B). A space forming portion to be described later is formed by the step portion 1702, the plate-like convex portion forming concave portion 1704, and the columnar convex portion forming concave portion 1705. The female mold 170 is provided with a gas-liquid flow passage 1706 that opens on the surface of the molding portion 1700 inside the female mold 170.

  Adjacent plate surface portions (inner surface portions) 1704A of the plate-shaped convex portion forming concave portions 1704 are provided at a part of the conical surface. The conical surface as the inner surface portion 1704A is preferably provided so that the apex S is positioned at the axis C of the outer peripheral edge 1704C and the inner peripheral edge 1704D of the plate-shaped convex portion forming concave portion 1704, but the effect obtained by the present invention. The apex may deviate from the axis C and the base surface portion 1703 within a range that does not affect the above.

  As shown in FIGS. 17 and 19, the male mold 180 is provided with a molding portion 1800 corresponding to the inner surface shape (outer shape of the cast body) of the recess 131 of the obtained mold 130A. The surface of the molded part 1800 is coated with a fluororesin. The molding part 1800 has a base surface part 1801 and a convex part 1802 protruding from the base surface part 1801. The convex portion 1802 includes a plate-like convex portion 1803 having a semicircular cross section arranged in parallel in a predetermined direction at a predetermined interval, and a columnar convex portion 1804 having a semicircular cross section provided so as to connect the plate-like convex portion 1803. is doing. The plate-like convex portion 1803 and the columnar convex portion 1804 are provided so that the centers of the semicircular cross sections are located on the same axis. Both end portions of the columnar convex portion 1804 project outward from the plate surface portion 1803B outside the plate-shaped convex portion 1803. The base surface portion 1801 and the convex portion 1802 of the molding portion 1800 are provided with a gas-liquid flow passage 1805 that opens on the surface thereof inside the male mold 180.

  Adjacent plate surface portions (inner surface portions) 1803A of the plate-like convex portions 1803 are provided on a part of a conical surface having a vertex S on the axis C of the circular cross section of the plate-like convex portion 1803 on the base surface portion 1801. It has been. The conical surface as the inner surface portion 1803A is preferably provided so that the vertex S is located on the axial center C of the circular cross section of the plate-like convex portion 1803 and the columnar convex portion 1804, but it has an influence on the effect obtained by the present invention. The apex may deviate from the axis C and the base surface portion 1801 within a range that does not reach. The gradient α of the conical surface as the plate surface portion 1803A is the difference in diameter between the outer peripheral edge 1803C of the plate surface portion 1803A and the inner peripheral edge 1803D of the plate-like convex portion 1803 (the diameter of the semicircular cross section of the plate-like convex portion and the semicircle of the columnar convex portion). It is determined by the difference in diameter of the cross section) and the distance d between the outer peripheral edge and the inner peripheral edge (see FIG. 19B). The gradient α is preferably 0.1 to 10 degrees, more preferably 0.5 to 5 degrees, and more preferably 1 to 3 degrees. When the gradient α of the conical surface is within such a range, it can be easily removed from the production mold without damaging the fiber laminate, and the interval between the plate-like portions can be narrowed. The distance D between the plate surface portions 1803A is preferably 1 to 50 mm in that the cast body can be made compact.

  In the dry mold having the above-described configuration, the plate surface portion 1803A of the male plate-like convex portion 1803 is provided with the conical surface as described above. Yes. Therefore, it is possible to produce a mold suitable for producing a cast body in which the intervals between the plate-like portions are filled with a paper-made molded body that is thin and has no cracks.

Next, an apparatus for manufacturing the mold 130A will be described.
The mold 130A is manufactured in the same manner as the above-described manufacturing apparatus (FIG. 11 and the like), and when the molds 130A and 130B as described later are butted into a main mold, no gap is generated on the butted surface. In addition, a manufacturing apparatus having a function capable of sharpening the corners 133A and 133B of each other is used. The manufacturing apparatus will be described below.

  As shown in FIG. 20, the manufacturing apparatus 1 ′ for the mold 130 </ b> A includes a raw material supply unit 2, a papermaking unit 3, and a dry molding unit 5.

  The raw material supply means 2 includes an injection frame 210, a vertical movement mechanism 21 that moves the injection frame 210 up and down, and a slurry supply pipe 22 that supplies the raw material slurry into the injection frame 210. A valve 23 is provided in the slurry supply pipe 22.

  The papermaking means 3 includes a papermaking mold (manufacturing mold) 150 having the above-described male shape. A discharge pipe 11 leading to the suction pump 12 is connected to a gas-liquid flow passage 1507 provided in the papermaking unit 1500 of the papermaking mold 150. A valve 13 is disposed in the discharge pipe 11.

  The dry molding means 5 includes a female mold 170 for dry molding, a vertical movement mechanism 51 that moves the female mold 170 up and down, and a male mold 180 for dry molding. When the female mold 170 and the male mold 180 are brought into contact with each other, a gap (clearance) corresponding to the outer shape of the mold 130A to be molded is formed between these molds.

  The female mold 170 has the same configuration as the female mold 170 shown in FIGS. As shown in FIG. 20, the female mold 170 is moved up and down by the vertical movement mechanism 51. The female mold 170 is provided with a gas-liquid flow passage 1706 (see FIG. 17) opened in the molding portion 1700 inside the female mold 170. The gas-liquid flow passage 1706 is connected to a flow pipe 52 that leads to a suction pump and a compressor (both not shown). A valve 53 is disposed in the flow pipe 52. The female mold 170 includes a heater (heating means) 54 that heats the molding unit 1700.

  The male mold 180 has the same configuration as the male mold 180 described in FIGS. A discharge pipe 31 leading to the suction pump 32 shown in FIG. 20 is connected to a gas-liquid flow passage 1805 (see FIG. 17) opened on the surface of the molding part 1800 of the male mold 180. A valve 33 is disposed in the discharge pipe 31. A recess may be formed on the surface of the mold 130A at a portion corresponding to the opening of the gas-liquid flow passage 1805, and a protrusion may remain on the casting surface. Depending on the application field of the cast product, it may be necessary to finish the surface of the cast product with a machine tool. In such a case, the gas-liquid flow passage 1805 may be omitted. Although not shown in the drawing, a heater or the like (heating means) for heating the molding unit 1800 is disposed inside the molding unit 1800.

  As shown in FIG. 25, the manufacturing apparatus 1 ′ has a thick portion that forms a thick portion 144 </ b> A by bending the base portion of the flange portion 142 </ b> A of the fiber laminate 14 </ b> A to the papermaking die 150 and the female die 170 as will be described later. Forming means 7 is provided. When the papermaking mold 150 and the female mold 170 are combined, the thick part forming means 7 includes a separating means 70 for separating the outer edge portion of the flange portion 142A of the fiber laminate 14A from the papermaking mold 150, and the papermaking mold 150 and the female mold. The space forming portion 71 is disposed between the mold 170 and forms a bent space of the base portion.

  In the present embodiment, the separating means 70 is constituted by the gas-liquid flow passage 1706 opening at the above-described step portion, the flow pipe 52 connected to the gas-liquid flow passage 1706, and the suction pump. Further, the space forming portion 71 is constituted by a recess 1510 of the papermaking mold 150 and a step portion 1703 of the female mold 170. Further, the gas-liquid flow passage 1706 may be more densely piped than other portions so that the suction force acts strongly on the outer edge portion of the flange portion of the fiber laminate 14A in the step portion 1703.

  The manufacturing apparatus 1 ′ includes moving means (not shown) that moves the papermaking mold 150 and the male mold 180 to a predetermined position along the guide 60 shown in FIG. 20. The manufacturing apparatus 1 ′ includes control means (not shown) provided with a sequencer that is connected to each of the above-described means and operates each of the means according to a procedure that will be described later.

Next, a manufacturing method of the mold 130A using the manufacturing apparatus 1 ′ will be described with reference to the drawings.
In the mold manufacturing method of the present embodiment, after making the wet fiber laminate 14A from the raw material slurry containing the respective components constituting the mold, the fiber laminate 14A is transferred from the papermaking mold 150 to the female mold 170, The fiber laminate 14A is press-molded between the female mold 170 and the male mold 180 to produce a mold 130A.

  In the present embodiment, first, a raw material slurry is prepared by dispersing the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and the thermally expandable particles in a dispersion medium. The raw slurry is prepared so as to be compatible with the mold to be produced. Examples of the dispersion medium include water, white water, solvents such as ethanol and methanol, and mixed systems thereof. Water is particularly preferable from the viewpoints of stability of papermaking and dehydration molding, stability of the quality of the molded body, cost, and ease of handling.

  In addition to the above-mentioned components, other ingredients such as a paper strength enhancer such as polyvinyl alcohol, carboxymethyl cellulose (CMC), and polyamidoamine epichlorohydrin resin, a flocculant, and a colorant are added to the raw material slurry in an appropriate ratio. You can also.

  In the paper making process of the mold 130 </ b> A, as shown in FIG. 21, the injection frame 210 is lowered by the vertical movement mechanism 21, the valve 23 is opened, and the slurry is supplied into the injection frame 210 through the slurry supply pipe 22. When the supply amount of the slurry reaches a predetermined amount, the valve 23 is closed and the supply of the slurry is stopped. Then, the valve 13 is opened, and the liquid component of the slurry is sucked by the suction pump 12 through the gas-liquid flow passage 1507 and the discharge pipe 11, and the solid component is deposited on the surface of the papermaking net 1508 and is wet. A body 14A is formed. The liquid content in the fiber laminate 14A is determined by the handling properties of the fiber laminate 14A and the deformation of the fiber laminate 14A due to the flow of fibers when the fiber laminate 14A is pressed between the female mold 170 and the male mold 180. In consideration of the above, the liquid content is preferably 50 to 200 parts by mass, and more preferably 70 to 100 parts by mass with respect to 100 parts by mass of the solid content in the fiber laminate 14A. The liquid content is adjusted by suction of the liquid component through the suction pump 12, and the suction is stopped so as to reach a predetermined liquid content.

  When the paper making of the fiber laminate 14A is finished, as shown in FIG. 22, the injection frame 210 is pulled up by the vertical movement mechanism 21, and the paper making mold 150 is moved below the female mold 170 along the guide 60 by the moving means. It is.

  Next, the female mold 170 is lowered by the vertical movement mechanism 51 and is brought into contact with the papermaking mold 150. Then, as shown in FIG. 25, the concave space 1510 of the papermaking mold 150 and the stepped portion 1703 of the female mold 170 form a bent space (the aforementioned space forming portion 71) of the base portion of the flange portion 142A of the fiber laminate 14A. .

  When the fiber laminate 14 </ b> A is removed from the papermaking mold 150, the fiber laminate 14 </ b> A is adsorbed to the molding unit 1700 side through the flow pipe 52 in the female mold 170. And at this time, as shown in FIG. 26, the outer edge portion of the flange portion 142A of the fiber laminate 14A is sucked through the gas-liquid flow passage 1706 opened at the step portion 1703 and separated from the papermaking mold 150. The base portion of the flange portion 142A is bent to form a thick portion 144A.

  When the female mold 170 is pulled up by the vertical movement mechanism 51 as shown in FIG. 26, the fiber laminate 14 </ b> A is delivered from the papermaking mold 150 to the female mold 170. Then, the male mold 180 is moved to a dry molding position with the female mold 170 by the moving means. As shown in FIGS. 27 and 28, the fiber laminate 14A made and formed in this manner has a corner portion formed at the intersection of the flange portion 142A and the inner surface of the recess portion 141A in the flange portion 142A. A thick portion 144A is formed at the edge of 143A.

Next, as shown in FIG. 23, the female mold 170 is lowered by the vertical movement mechanism 51. Then, the fiber laminate 14A is pressed against the male mold 180 heated to a predetermined temperature and pressed between these male and female molds, and a dried mold 130A is obtained. By this press molding, the apex of the corner portion 133A formed at the intersection of the inner surface of the recess 131A and the flange portion 132A in the mold 130A becomes sharp. It should be noted that when the female mold 170 and the male mold 180 are abutted with each other, a space for accommodating the thick portion 144A is not formed. That is, a gap corresponding to the shape of the mold to be finally formed (having no thick portion) is formed. When the apex of a sharp corner comes into contact with another object, the apex is easily damaged because of the sharpness. Therefore, the density of the apex of the corner is 0.8 g / cm ³ or more to prevent damage. It is desirable.

  The mold temperatures of the female mold 170 and the male mold 180 are appropriately set according to the mold 130A to be manufactured. However, in consideration of prevention of scorching of the fiber laminate 14A, etc., 100 to 250 ° C is preferable, and 120 to 200 ° C is preferable. More preferred. The pressure of the press molding by the female mold 170 and the male mold 180 is preferably 0.2 MPa to 10 MPa, and more preferably 0.5 MPa to 5 MPa in consideration of reliably crushing the thick portion. However, the pressure of press molding may vary greatly depending on the type and strength of the material constituting the mold 130A.

  During dry molding, the valve 33 is open, and the moisture in the fiber laminate 14A is sucked by the suction pump 32 via the gas-liquid flow passage 1805 (see FIG. 17) and the discharge pipe 31 and discharged to the outside. . On the other hand, the injection frame 210 is lowered by the vertical movement mechanism 21, and the papermaking portion 1500 of the papermaking mold 150 is included in the injection frame 210 again. Then, the fiber laminate is newly made in the same manner as in the paper making step.

  When the dry molding process is completed, the suction from the flow pipe 52 is switched to the air injection by the compressor, and the female mold 170 is pulled up by the vertical movement mechanism 51 as shown in FIG. Then, after the suction by the suction pump 32 is stopped, the mold 130A remaining on the male mold 180 side is removed from the male mold 180, and the manufacture of the mold 130A is completed. Moreover, the injection frame 210 is pulled up by the vertical movement mechanism 21, and the new fiber laminated body 14A which finished the papermaking process is moved to a heating process after that. In the manufacturing method of the present embodiment, such paper making and dry forming steps are repeated.

  The molds 130A (and 130B) manufactured in this way are butted at their butting surfaces, used as a main mold as a composite mold, and further provided with a runner pipe etc. and embedded in casting sand to form a mold. A cast body can be manufactured by supplying molten metal into the cavity of the main mold. In this case, as shown in FIG. 29, when the abutting surfaces of the flange portions 132 (132A, 132B) face each other, the corners 133 (133A, 133B) have sharp apexes. Since a gap is not substantially formed in the butt portion between the parts, burrs do not occur in the obtained cast body.

  As described above, the molds 130A and 130B can be suitably manufactured by using the manufacturing molds of the present embodiment (papermaking mold and male and female molds for drying). Further, by using the molds 130A and 130B, a cast body that exhibits the above-described effects can be suitably manufactured.

Next, an embodiment will be described in which a mold made of the above-mentioned papermaking molded body is used as a wooden mold (mold manufacturing mold) used for manufacturing a conventional sand mold.
The mold 130A is lightweight, and as described above, a mold having the same shape can be mass-produced with the manufacturing mold. The mold 130A can be similar in shape to the outer shape of the cast body that casts the outer shape of the concave portion 131A (corresponding to the convex portion 41 in FIG. 6). In this case, the mold 130A can be used as a substitute for a wooden mold (mold manufacturing mold) conventionally used for manufacturing a mold (sand mold) using cast sand. When the mold 130A is a wooden substitute, the outer surface of the plate-like convex forming recess 1311 of the concave portion 131A is a plate-like convex portion (corresponding to the plate-like convex portion 411 in FIG. 6). The adjacent plate surface portions (inner surface portions) of the convex portions are provided as part of the conical surface (the inner surface portion corresponds to 411A in FIG. 7). Further, a plate surface portion (corresponding to 411B in FIG. 7) outside the plate-like convex portion is also provided as a part of the conical surface. Therefore, the mold 130A as a substitute for the wooden mold is provided with a conical surface on both the inner and outer plate surface portions of the plate-like convex portion. Can be easily separated.

  The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit of the present invention.

  In the above embodiment, adjacent inner surface portions of the concave portions for forming the plate-like convex portions of the mold, papermaking mold, dry mold, papermaking molded body, and adjacent inner surface portions of the plate-like convex portions are part of the conical surface. Although provided, it may be provided as a part of a hyperboloid instead of the conical surface. Moreover, when using a casting_mold | template as a substitute of the above-mentioned wooden type | mold, you may provide the board surface part of the both sides inside and outside of a plate-shaped convex part by a part of a hyperboloid instead of a conical surface. Here, the hyperboloid surface in this specification means a curved surface drawn when a curved line intersecting with a straight line is made to go around. Note that the angle at which the straight line and the curve intersect when the curved line that intersects with the straight line is rounded around one straight line is not limited to a range that does not impair the effects of the present invention, and even if it is not constant, it changes during the rounding. You may let them.

  Although each columnar convex part and plate-shaped convex part have been described as a semi-cylindrical shape, another shape such as a rectangular column or a semi-elliptical column may be used.

  Moreover, although the two plate-like convex portions have been described, two or more plate-like convex portions may be formed depending on the purpose of use.

Hereinafter, the present invention will be described more specifically.
As in Example 1 and Comparative Example 1 below, a fiber laminate of a papermaking molded product having the following dimensional shape was produced. The moldability and demoldability of the resulting papermaking molded product were evaluated as follows.

[Example 1]
Using a papermaking mold as shown in FIG. 30, a fiber laminate of a papermaking molded body was produced in which the adjacent inner surface portions of the plate-like convex portions were provided as part of a cone.

<Raw material>
Ratio of organic fiber (new newspaper) 4, inorganic fiber (carbon fiber) 4, inorganic powder (graphite powder) 76, thermosetting resin (phenol resin) 12, and thermally expandable particles 4 (each numerical value is parts by mass) The blended raw materials were dispersed in water, and a slurry with a solid content concentration of about 3% by mass was prepared and made.

<Making paper>
Material of papermaking mold body: Aluminum alloy Main dimensions of papermaking mold L = 288.5 (mm)
W1 = 13 (mm)
W2 = 9 (mm)
D = 3 (mm)
A1 = 32.4 (mm)
A2 = 32.4 (mm)
A3 = 20 (mm)
d1 = 0.65 (mm)
d2 = 0.65 (mm)
α = 3 (degrees)
Paper making net: wire diameter 0.19mm, mesh # 40 mesh, material is stainless steel.

<Dehydration conditions>
Dehydration method: Suction dehydration with a waterproof vacuum cleaner Dehydration time: 60 seconds Water content after dehydration: 30-80%

[Comparative Example 1]
Using the papermaking mold as shown in FIG. 31, the fiber of the papermaking molded body in which a plate-like convex part on the base surface part of the papermaking part is given a draft in a plane (two-dimensional) with respect to the base surface part. A laminate was produced.

<Raw material>
Ratio of organic fiber (new newspaper) 4, inorganic fiber (carbon fiber) 4, inorganic powder (graphite powder) 76, thermosetting resin (phenol resin) 12, and thermally expandable particles 4 (each numerical value is parts by mass) The blended raw materials were dispersed in water, and a slurry with a solid content concentration of about 3% by mass was prepared and made.

<Making paper>
Material of papermaking mold body: Aluminum alloy Main dimensions of papermaking mold L = 288.5 (mm)
W1 = 13 (mm)
W2 = 9 (mm)
D = 3 (mm)
B1 = 32.4 (mm)
B2 = 32.4 (mm)
B3 = 20 (mm)
u1 = 1 (mm)
u2 = 1 (mm)
Paper making net: wire diameter 0.19mm, mesh # 40 mesh, material is stainless steel.

<Dehydration conditions>
Dehydration method: Suction dehydration with a waterproof vacuum cleaner Dehydration time: 60 seconds Water content after dehydration: 30-80%

<Evaluation method for paper-molded compact>
After visually observing the appearance of the obtained fiber laminate and confirming the presence or absence of cracks or the like, the fiber laminate is demolded while vacuum suction using the female mold 20 shown in FIG. Confirmed the condition of body damage.

In the fiber laminate of the paper-molded article obtained in Example 1, the occurrence of defects such as cracks could not be visually confirmed. Next, the female mold 20 shown in FIG. 8 was used for demolding while vacuum suctioning, but it was possible to demold from the papermaking mold 10 without damaging the fiber laminate.
On the other hand, in the fiber laminate of the paper-molded article obtained by Comparative Example 1, it is visually observed that the fiber is insufficiently laminated at P part in FIG. 32 and there is a portion where no cracks or fibers are laminated. I was able to confirm. Therefore, the demolding test was abandoned while vacuum suction was performed using the female mold shown in FIG.

  INDUSTRIAL APPLICABILITY The present invention is suitable for providing a papermaking mold, a dry molding mold, and a papermaking molded body suitable for producing a papermaking molded body in which the intervals between the plate-like convex portions are tight.

  The present invention is particularly suitable for a mold, but can also be applied to a casting mold having other shaft portions and plate-like convex portions cast integrally with the shaft portions. For example, it can be applied to a wheel shaft with a stopper. In this case, a portion corresponding to the plate-like convex portion is a disc-shaped stopper, and when the casting wheel is fitted to the shaft, the casting wheel can be positioned by the disc-like stopper. As another example, it is also suitable for a shape in which a plurality of disc-shaped rollers are attached to the shaft, such as a paper feed roller of a printer. Furthermore, it is also suitable for manufacturing a heat radiating part (fin) of a motorcycle engine case. As described above, the present invention is suitable for manufacturing molds of various shapes having a narrow gap.

It is a figure which shows one Embodiment of the papermaking type | mold of this invention, (a) is a perspective view, (b) is AA arrow sectional drawing. It is a figure which shows the external shape of the type | mold main body in one Embodiment of the papermaking type | mold of this invention, (a) is a XX arrow directional view in FIG. 1, (b) is a top view of (a). It is a perspective view which shows one Embodiment of the dry shaping | molding die used in the manufacture process of the papermaking molded object of this invention. It is a figure which shows one Embodiment of the female type | mold of the dry shaping | molding die used in the manufacture process of the papermaking molded object of this invention, (a) is a side view, (b) is a bottom view of (a). It is a figure which shows one Embodiment of the male mold | die of the dry mold used in the manufacture process of the papermaking molded object of this invention, (a) is a side view, (b) is a top view of (a). It is a perspective view which shows one Embodiment of the papermaking molded object of this invention. It is a figure which shows one Embodiment of the papermaking molded object of this invention, (a) is a longitudinal cross-sectional view, (b) is a bottom view. It is a figure which shows typically one Embodiment of the manufacturing apparatus of the papermaking molded object of this invention. It is a figure which shows typically the papermaking process in one Embodiment of the manufacturing method of the papermaking molded object by the said manufacturing apparatus. It is a figure which shows typically the transfer process of the fiber laminated body after completion | finish of the papermaking process in one Embodiment of the manufacturing method of the papermaking molded object by the said manufacturing apparatus. It is sectional drawing which shows typically the dry-molding process in one Embodiment of the manufacturing method of the papermaking molded object by the said manufacturing apparatus. It is a figure which shows typically the demolding state after completion | finish of the dry-molding process in one Embodiment of the manufacturing method of the papermaking molded object by the said manufacturing apparatus. It is a perspective view which shows typically the state before combining one Embodiment of the casting_mold | template of this invention as a composite casting_mold | template. It is a figure which shows one Embodiment of the casting_mold | template of this invention, (a) is a longitudinal cross-sectional view, (b) is a bottom view. It is a figure which shows one Embodiment of the papermaking type | mold used in the manufacture process of the casting_mold | template of this invention, (a) is a perspective view, (b) is AA arrow sectional drawing. It is a figure which shows the external shape of the type | mold main body in one Embodiment of the papermaking type | mold used in the manufacture process of the casting_mold | template of this invention, (a) is a XX arrow line view in FIG. 15, (b) is a plane of (a). FIG. It is a perspective view which shows one Embodiment of the dry shaping | molding die used in the manufacture process of the casting_mold | template of this invention. It is a figure which shows one Embodiment of the female die of the dry shaping | molding die used in the manufacture process of the casting_mold | template of this invention, (a) is a side view, (b) is a bottom view of (a). It is a figure which shows one Embodiment of the male die of the dry mold used in the manufacture process of the casting_mold | template of this invention, (a) is a side view, (b) is a top view of (a). It is a figure which shows typically one Embodiment of the manufacturing apparatus of the casting_mold | template of this invention. It is a figure which shows typically the papermaking process in one Embodiment of the manufacturing method of the casting_mold | template by the said manufacturing apparatus. It is a figure which shows typically the transfer process of the fiber laminated body after the papermaking process in one Embodiment of the manufacturing method of the casting_mold | template by the said manufacturing apparatus. It is a figure which shows typically the dry-molding process in one Embodiment of the manufacturing method of the casting_mold | template by the said manufacturing apparatus. It is a figure which shows typically the demolding state after completion | finish of the dry molding process in one Embodiment of the manufacturing method of the casting_mold | template by the said manufacturing apparatus. It is sectional drawing which shows typically the formation process of the thick part by the said manufacturing apparatus. It is sectional drawing which shows typically the demolding process of the casting_mold | template by the said manufacturing apparatus. It is a perspective view which shows typically the fiber laminated body used for manufacture of one Embodiment of the casting_mold | template of this invention. It is a principal part expanded sectional view of the fiber laminated body used for manufacture of one Embodiment of the casting_mold | template of this invention. It is a principal part expanded sectional view of the butt | matching part at the time of combining the casting_mold | template of this invention and using it as a composite casting_mold | template. It is a figure which shows the external shape of the type | mold main body in the Example of the papermaking type | mold of this invention, (a) is a side view, (b) is a top view of (a). It is a figure which shows the external shape of the type | mold main body in the comparative example of the papermaking type | mold of this invention, (a) is a side view, (b) is a top view of (a). It is a figure which shows the external shape of the type | mold main body for demonstrating the P section in the said comparative example, (a) is a side view, (b) is a top view of (a).

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Papermaking type | mold 10A type | mold main body 102 Base surface part 105 Plate-shaped convex part 105A Inner surface part 106 Columnar convex part 108 Papermaking net | network 40 (40A, 40B) Papermaking molded object 411 Plate-shaped convex part 411A Plate surface part (inner surface part)
412 Columnar convex portion 420 Substrate portion 421 Base surface portion 130 (130A, 130B) Composite mold (mold)
131 Concave part 1311 Concave part for forming plate-like convex part 1311A Inner surface part 1312 Concave part for forming columnar convex part 1321 Base surface part

Claims (22)

  A papermaking mold provided with a papermaking net disposed in a papermaking portion of the die body and the papermaking portion of the mold body, having a columnar convex portion lying on the base surface portion of the papermaking portion, and in the length direction of the columnar convex portion A papermaking mold in which two or more plate-like convex portions are formed at predetermined intervals at a predetermined interval, and adjacent inner surface portions of the plate-like convex portions are provided as a part of a conical surface or a hyperboloid.   The papermaking mold according to claim 1, wherein a cross section in the length direction of the columnar convex portion is a semicircular shape.   The papermaking mold according to claim 1 or 2, wherein a gradient of the conical surface or the hyperboloid is 0.1 to 10 degrees.   The papermaking mold according to any one of claims 1 to 3, wherein a gap between the inner surface portions is 1 to 50 mm.   A paper-molded molded article having a flange portion, which has a columnar convex portion lying on a substrate portion including the flange portion, and the plate-shaped convex portions at predetermined positions in the length direction of the columnar convex portion. And two or more formed, and the adjacent inner surface portions of the plate-like convex portions are provided with a part of a conical surface or a hyperboloid.   The papermaking molded product according to claim 5, wherein a cross section in the length direction of the columnar convex portion is a semicircular arc shape.   The papermaking molded product according to claim 5 or 6, wherein a gradient of the conical surface or the hyperboloid is 0.1 to 10 degrees.   The papermaking molded product according to any one of claims 5 to 7, wherein a gap between the inner surface portions is 1 to 50 mm.   A mold having a concave portion that becomes a molding surface of a cast body in which a plurality of plate-like portions are cast at a predetermined interval, and the concave portion is recessed from a base surface portion and arranged in parallel at a predetermined direction. A mold having a plurality of plate-shaped convex portion forming concave portions, wherein the adjacent inner surface portions of the plate-shaped convex portion forming concave portions are provided as part of a conical surface or a hyperboloid.   The mold according to claim 9, wherein the concave portion has a concave portion for forming a columnar convex portion extending so as to connect the plurality of concave portions for forming the plate-shaped convex portion.   The mold according to claim 9 or 10, wherein a gradient of the conical surface is 0.1 to 10 degrees.   The mold according to any one of claims 9 to 11, wherein a gap between the inner surface portions is 1 to 50 mm.   The mold according to any one of claims 9 to 12, comprising a papermaking molded product.   A composite mold in which a plurality of the molds according to any one of claims 9 to 13 are combined with the base surface portion as a butting surface.   A dry mold comprising a pair of female molds and male molds used in the manufacture of the paper-molded molded article according to claim 5, wherein when the female mold and the male mold are brought into contact with each other, A dry mold in which a gap corresponding to the outer shape of the papermaking molded body to be formed is formed.   A male mold constituting the dry mold according to claim 15, having a columnar convex portion lying on the base surface portion of the molded portion, and having a plate shape at a predetermined position in the length direction of the columnar convex portion. A male mold constituting a dry mold in which two or more convex portions are formed at a predetermined interval, and the adjacent inner surface portions of the plate-shaped convex portions are provided as part of a conical surface or a hyperboloid.   A female mold constituting the dry mold according to claim 15, comprising a concave molded portion in which the outer shape of the resulting paper-molded molded body is directly opposite to the concave and convex portions, and the molded portion is formed of the paper-molded molded body. A female mold constituting a dry mold in which two or more concave portions corresponding to the plate-like convex portions are formed at a predetermined interval, and adjacent inner surface portions of the concave portions are provided by a part of a conical surface or a hyperboloid. .   A dry mold comprising a pair of female molds and a male mold used for producing the mold according to claim 9, wherein when the female mold and the male mold are brought into contact with each other, a mold is formed between these molds. A dry mold in which a gap corresponding to the outer shape of the mold is formed.   A male mold constituting the dry mold according to claim 18, having a columnar convex portion lying on the base surface portion of the molded portion, and having a plate shape at a predetermined position in the length direction of the columnar convex portion. A male mold constituting a dry mold in which two or more convex portions are formed at a predetermined interval, and the adjacent inner surface portions of the plate-shaped convex portions are provided as part of a conical surface or a hyperboloid.   A female mold constituting the dry mold according to claim 18, comprising a concave molded portion in which the outer shape of the obtained mold is directly opposite to the concave and convex portions, and the molded portion is a plate-shaped convex portion of the mold. Is a female mold that constitutes a dry mold in which two or more recesses corresponding to 1 are formed at predetermined intervals, and adjacent inner surface portions of the recesses are provided as part of a conical surface or a hyperboloid.   After making a wet fiber laminate from the raw slurry using the papermaking mold according to claim 1, the fiber laminate is transferred from the papermaking mold to the female mold according to claim 17, The manufacturing method of the papermaking molded object which press-molds the said fiber laminated body between the male type | molds of Claim 16, and manufactures a papermaking molded object.   After making a wet fiber laminate from the raw slurry using the papermaking mold according to claim 1, the fiber laminate is transferred from the papermaking mold to the female mold according to claim 20, A mold manufacturing method for press-molding the fiber laminate with the male mold according to claim 19 to manufacture a mold.

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