JP2009000847A - Master model and manufacturing method for master model - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a master model which is capable of reducing its weight, and thus of improving the working efficiency in the manufacture of a molding mold, and further of being manufactured even with a compact manufacturing apparatus, and a manufacturing method for the master model. <P>SOLUTION: The master model 10 is for manufacturing the molding mold 8 for solid finished products. The inside part is formed to be hollow, divided into a plurality of division master models 11-16. The division master models 11-16 are connected with each other through a connecting part 9 provided on the division master models 11-16, and one or more of ribs 22 are formed on the inner surface 19A of a hollow part 19 of the division master models 11-16. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

The present invention
The present invention relates to a master model for producing a mold for a solid product such as a seat cushion pad or a seat back pad.

  Conventionally, when producing a master model for producing a mold for a solid product, a resin material such as hard urethane is attached to the table of an NC machine tool, and the outer surface of the resin material is roughened, finished, etc. The master model was formed into a solid unit by precisely cutting over multiple stages.

  According to the above conventional technique, since the master model is formed as a solid unit, the master model is heavy, and it takes time to handle the master model in the process of manufacturing the mold.

  As a result, the working efficiency of the mold production work has been low. In addition, master model manufacturing apparatuses such as NC machine tools have become larger.

  The present invention has been made in view of the above circumstances, and its purpose is to reduce the weight, improve the working efficiency of the mold manufacturing work, and can be manufactured by a small manufacturing apparatus. It is in providing a manufacturing method of a model and a master model.

The structure, operation, and effect of the invention of claim 1 (first invention) are as follows.
[Constitution]
A master model for producing molds for solid products,
Forming the inside hollow,
While dividing | segmenting into a some division | segmentation master model, the said division | segmentation master models are connected through the connection part provided in the said division | segmentation master model.

[Action / Effect]
According to this configuration, since the inside of the master model is formed hollow, it is possible to suppress the weight of the master model, and the master model is not time-consuming to handle. The model can be made easier to handle. Therefore, it is possible to improve the working efficiency of the mold manufacturing work.
In addition, the divided master models are divided into a plurality of divided master models, and the divided master models are connected to each other via a connecting portion provided in the divided master model, so that the divided master models can be manufactured separately, and the master model is reduced in size. Even a manufacturing apparatus of can be manufactured.

The structure / action / effect of the invention of claim 2 is as follows.
[Constitution]
In the structure of the invention according to claim 1,
One or more ribs are formed on the inner surface of the hollow portion of the divided master model.

[Action / Effect]
In addition to the operations and effects of the configuration of the first aspect, the following operations and effects can be achieved.
Since one or more ribs are formed on the inner surface of the hollow part of the divided master model, the strength and rigidity of the divided master model can be increased, and the master model formed by connecting multiple divided master models is hollow. Despite being configured, the strength and rigidity of the master model can be increased. As a result, deformation of the master model can be avoided, and the master model can be accurately formed in a target shape.

The structure, operation, and effect of the invention of claim 3 are as follows.
[Constitution]
In the configuration of the invention according to claim 2,
The one or more ribs are laid between opposing inner surfaces of the hollow portion of the divided master model to partition the hollow portion into a plurality of hollow portion portions, and each hollow portion portion is divided into the divided master model. And communicated with the external space through the opening of the divided portion.

[Action / Effect]
In addition to the above-described operation / effect, the following operation / effect can be achieved.
Since the one or more ribs are installed between the opposing inner surfaces of the hollow portion of the divided master model, the strength and rigidity of the divided master model can be further increased, and a plurality of divided master models can be provided. Even though the connected master model is hollow, the strength and rigidity of the master model can be increased. As a result, deformation of the master model can be avoided, and the master model can be accurately formed in a target shape.
Moreover, since the hollow part of the division | segmentation master model is divided into several hollow part parts, and each hollow part is connected with external space through the opening of the division | segmentation part of a division | segmentation master model, for example, 1 or 2 or more Compared to a structure in which a hollow portion sealed with ribs is formed, it can be easily manufactured.

The structure, operation and effect of the invention of claim 4 are as follows.
[Constitution]
In the structure of the invention according to any one of claims 1 to 3,
All of the plurality of divided master models are formed hollow.

[Action / Effect]
The above-mentioned operation and effect of any one of claims 1 to 3 can be obtained more easily.

The structure, action, and effect of the invention of claim 5 (second invention) are as follows.
[Constitution]
A method for producing a master model according to any one of claims 1 to 4,
Creating a three-dimensional model of the divided master model, and slicing the three-dimensional model at a predetermined pitch to create a plurality of slice-shaped slice data;
A layered body of a shape corresponding to each slice data is formed with a layered manufacturing apparatus and laminated to produce the divided master model,
After the plurality of divided master models are manufactured by the additive manufacturing apparatus, the plurality of divided master models are connected to each other via the connecting portion to manufacture the master model.

[Action / Effect]
A three-dimensional model of the divided master model is created, and slice data of a slice shape is created by slicing the three-dimensional model at a predetermined pitch.
Then, a layered body having a shape corresponding to each slice data is formed by a layered manufacturing apparatus and stacked to manufacture the divided master model. After manufacturing a plurality of divided master models in this way, a plurality of divided master models are connected to each other through the connecting portion to manufacture a master model.

  By producing a master model as described above, the following effects can be obtained.

For example, when a master model is manufactured by cutting the outer surface of a hard resin material with an NC machine tool, there are the following problems in addition to the problems described above.
(1) Chips are generated and the processing is troublesome.
(2) Since the outer surface of the hard resin material is cut in a plurality of stages such as roughing and finishing, the time required for the cutting is long and the processing is expensive.

  On the other hand, according to the above means of the present invention, the additive manufacturing apparatus for manufacturing each master model of the master model is generally a small machine as compared with the NC machine tool which is a cutting machine, and is not a large factory. Can be installed. In addition, since the additive manufacturing apparatus is not a cutting machine, it does not generate chips, can save labor for processing chips, and can reduce processing time.

  Even when a master model is manufactured using an additive manufacturing apparatus, if the master model is solid, a large amount of material is required, which increases the material cost and the manufacturing cost. Therefore, since the master model is hollow, the cost required for the material can be reduced. In addition, the master model can be reduced in weight compared to the solid master model.

The configuration, action, and effect of the invention of claim 6 (second invention) are as follows.
[Constitution]
In the structure of the invention according to claim 5,
The additive manufacturing apparatus is an apparatus that stacks a plurality of powder layers by alternately repeating an operation of forming a powder layer on a table and an operation of forming an adhesive layer on the powder layer,
An adhesive layer having a shape corresponding to each slice data is separately formed on each powder layer,
The powder layer portion to which the adhesive layer adheres is configured in the layered body, the layered bodies positioned with the adhesive layer sandwiched therebetween are connected by the adhesive layer, and the powder to which the adhesive layer is not bonded The divided master model is manufactured by removing.

[Action / Effect]
A three-dimensional model of the divided master model is created, and slice data of a slice shape is created by slicing the three-dimensional model at a predetermined pitch.
Then, using an additive manufacturing apparatus that laminates the powder layer by alternately repeating the operation of forming the powder layer on the table and the operation of forming the adhesive layer on the powder layer, The adhesive layer having a shape corresponding to each slice data is formed separately, the powder layer portion to which the adhesive layer adheres is formed into the layered body, and the layered bodies positioned with the adhesive layer sandwiched are bonded together. Connect with the agent layer.
Thereafter, the powder to which the adhesive layer is not adhered is removed to manufacture a divided master model. After manufacturing a plurality of divided master models in this way, a plurality of divided master models are connected to each other through the connecting portion to manufacture a master model.

  In the manufacturing process of the divided master model, when removing the powder not adhered to the adhesive layer, the powder can be removed through the opening of the divided portion of the divided master model. By producing the master model in this way, the same operational effects as the above-described operational effects can be achieved.

  Even when a master model is manufactured using an additive manufacturing apparatus, if the master model is solid, a large amount of powder is required, which adds to the cost of the powder, increases the material cost, and increases the manufacturing cost. However, according to the above means of the present invention, the master model is hollow, and the powder in the hollow portion is removed through the opening, so that the powder can be reused and the cost required for the powder can be reduced. Can do. Further, compared to a solid master model, the amount of powder constituting the master model can be reduced, and the master model can be reduced in weight.

The structure, operation, and effect of the invention of claim 7 are as follows.
[Constitution]
In the structure of the invention according to claim 5 or 6,
The solid product is a seat cushion pad or a seat back pad.

[Action / Effect]
When manufacturing a master model for manufacturing a mold for a seat cushion pad or a seat back pad, the same operation / effect as the above-described operation / effect can be achieved.

According to the present invention,
It was possible to reduce the weight, improve the working efficiency of the mold manufacturing work, and provide a master model that can be manufactured even with a small manufacturing apparatus, and a method for manufacturing the master model.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 4 show a seat cushion pad P (corresponding to a solid product) for an automobile seat. 1 is a perspective view of the seat cushion pad P, FIG. 2 is a plan view of the seat cushion pad P, FIG. 3 is a bottom view of the seat cushion pad P, and FIG. 4 is a side view (left side view) of the seat cushion pad P. . The seat cushion pad P is covered with a skin material (not shown) to constitute a seat cushion. And the seat of a motor vehicle is comprised with the seat back which rises from the rear-end part of a seat cushion.

[Structure of seat cushion pad P]
The seat cushion pad P is solidly formed of foamed urethane or the like, and includes a pair of left and right raised side portions 1 and a center portion 2 between the side portions 1. The pair of left and right raised side portions 1 are along the front-rear direction (the vehicle front-rear direction), and hold the occupant's buttocks and thighs in the left-right direction to prevent positional displacement of the buttocks and thighs in the left-right direction. .

  Then, the rear end portion of the seat cushion pad P is formed to be narrow, a plurality of concave portions 3 are formed on the back surface portion (see FIG. 3), among the front surface portion, between the side portion 1 and the center portion 2, etc. Vertical and horizontal grooves 4 for drawing a skin material (not shown) are formed. The seat back rises from the vicinity of the narrow rear end of the seat cushion pad P. The vertical and horizontal grooves 4 are set in an H shape in plan view. The appearance of the seat cushion can be improved by drawing the skin material into the H-shaped groove 4.

  As shown in FIGS. 6 (a), 6 (b), 6 (c), 7 (a), 7 (b), and 7 (c), the upper surface of the side portion 1 is laterally outward. It is formed in the inclined surface located in the upper part, and the amount of protrusion of the side part 1 of the front-back direction intermediate part is larger than the amount of protrusion of the side part 1 of the front-back direction both ends (front-end part and rear-end part). . The outer surfaces of the pair of left and right side portions 1 are formed in a surface that is substantially straight in the vertical direction. Moreover, the back side of the side part 1 is scooped up, and the space is formed in the back side.

  A reinforcing cloth (not shown) is attached to the back surface of the seat cushion pad P. As shown in FIG. 3, the recesses 3 are arranged in a pair of left and right at the front end of the center portion 2, and one is arranged on the rear side between the pair of left and right recesses 3. The force applied to the thigh is weakened. The pair of left and right recesses 3 are formed in a square shape in a bottom view, and the one recess 3 is formed in a rounded triangular shape in a bottom view. The single recess 3 is located at the center in the left and right direction of the center portion 2 and slightly ahead of the center in the front-rear direction of the center portion 2.

  As shown in FIGS. 5, 6 (c), 7 (a), 7 (b), and 7 (c), a hook or the like provided on the back side of the skin material on the back side of the bottom of the groove 4. A wire 6 for locking the locking tool is embedded. At the bottom of the groove 4, a plurality of long holes 5 for engaging with the locking tools are formed in the longitudinal direction of the groove 4 at a predetermined interval. As shown in FIG. 6 (c), the wire 6 is arranged at substantially the same position in the vertical direction as the bottom surface of the elongated hole 5 for locking tool locking operation. Therefore, when the locking tool is inserted into the long hole 5 and locked to the wire 6, the locking tool can be easily locked. The elongated hole 5 is formed in an oval shape in plan view that is long in the longitudinal direction of the groove 4.

As shown in FIG. 21, the seat cushion pad P is formed by a lower mold 24 and an upper mold 25 that is supported by the lower mold 24 so that it can swing up and down around the horizontal axis O.
Explaining the molding process,
(1) With the upper mold 25 opened upward, the reinforcing cloth is set on the upper mold 25 and the wire 6 is set on the upper mold 25 (or the lower mold 24).
(2) A urethane stock solution as a foamed resin stock solution is supplied to the lower die 24, and the upper die 25 is swung down and overlapped with the lower die 24 and closed, and a cavity formed between the upper die 25 and the lower die 24 26, foam the urethane stock solution.
(3) When the foam molding is completed, the upper mold 25 is swinged upward around the horizontal axis O and removed.
The seat cushion pad P is formed upside down. Thereby, the surface on the front side which is the surface on the passenger side of the seat cushion pad P can be densely formed. Further, it is possible to make it difficult to form a thin wall on the front side surface.

  The molding die 8 (the seat cushion pad molding die 8, which is a mold) composed of the lower die 24 and the upper die 25 is manufactured according to the master model 10 of the seat cushion pad P. Next, the structure of the master model 10 for manufacturing the mold 8 for the seat cushion pad and the manufacturing method of the master model 10 will be described.

[Structure of master model 10]
As shown in FIG. 8, FIG. 9, FIG. 10 (a), FIG. 10 (b), and FIG. 10 (c), the outer surface shape of the master model 10 is set to be the same as the outer surface shape of the seat cushion pad P, The size of the master model 10 is set slightly larger than the seat cushion pad P in consideration of the shrinkage rate after demolding of the urethane foam-molded using the mold 8. Specifically, the size of the master model 10 is set to 20/1000 times the size of the seat cushion pad P that is a product.

  Further, the master model 10 is formed in a hollow shape, and one vertical division line L1 (line along the front-rear direction, see FIG. 8) passing through the left and right centers, and two horizontal lines that divide the master model 10 into front and rear approximately three equal parts. The master model 10 is divided into six front and rear and left and right sides (see FIG. 9) along the dividing line L2 (a line along the left and right direction, see FIG. 8).

  As a result, the master model 10 is divided into a left front division master model 11, a right front division master model 12, a left center division master model 13, a right center division master model Dell 14, and a left rear division. It consists of a master model 15 and a divided master model 16 on the right rear side. All the divided master models 11, 12, 13, 14, 15, 16 are hollow, and the divided master models 11, 12, 13, 14, 15, 16 are adjacent to each other via the connecting portion 9 provided in each divided master model 11, 12, 13, 14, 15, 16. Master models 11, 12, 13, 14, 15, 16 are connected to each other.

The connecting portion 9 is configured by distributing and arranging a plurality of connecting pins 9A and pin holes 9B to be fitted to adjacent divided master models 11, 12, 13, 14, 15, and 16.
Specifically, the connecting pin 9A and the pin hole 9B are distributed and arranged on the upper and lower ends of the rear end surface of the left front divided master model 11 (the rear divided surface, the same applies hereinafter), and the left front divided master model 11 is arranged. The connecting pin 9A and the pin hole 9B are distributed and arranged at the upper and lower ends of the right end surface (right divided surface, the same applies hereinafter).
Similarly, the connecting pin 9A and the pin hole 9B are distributed and arranged at both upper and lower ends of the rear end surface of the right front divided master model 12, and the left end surface (left divided surface, hereinafter referred to as the left divided surface) of the right front divided master model 12. The connecting pin 9A and the pin hole 9B are distributed and arranged at both upper and lower ends of the same).
Then, the connecting pin 9A and the pin hole 9B are distributed and arranged at the upper and lower ends of the front end face (the front divided face, the same applies hereinafter) of the left rear divided master model 15, and the left rear divided master model 11 is arranged. The connecting pin 9A and the pin hole 9B are distributed and arranged at both upper and lower end portions of the right end surface of the head.
Similarly, the connecting pin 9A and the pin hole 9B are distributed and arranged on the upper and lower ends of the front end surface of the right rear divided master model 16, and the upper and lower ends of the left end surface of the right rear divided master model 12 are arranged. The connecting pin 9A and the pin hole 9B are arranged in a distributed manner.

  The pair of left and right center divided master models 13 and 14 includes a front end surface, a rear end surface, a left end surface (in the case of the right center divided master model 14) and a right end surface (in the case of the left center divided master model 13). A connecting pin 9A and a pin hole 9B are distributed and arranged at both ends. Both the connecting pin 9A and the pin hole 9B have a circular cross section.

  In the above connecting structure, a pin hole 9B is provided in place of the connecting pin 9A of each divided master model 11, 12, 13, 14, 15, 16 and each divided master model 11, 12, 13, 14, 15, 16 is provided. The opposed pin holes 9B may be connected to each divided master model 11, 12, 13, 14, 15, 16 via pins 9A that are separate from each other. That is, half of the pin 9A in the axial direction is fitted into one pin hole 9B, and the other half is fitted into the other pin hole 9B. Next, a method for manufacturing the master model 10 having the above structure will be described.

[Manufacturing Method of Master Model 10]
The divided master models 11, 12, 13, 14, 15, 16 are separately manufactured one by one using the 3D printer 30 as the additive manufacturing apparatus, and the adjacent divided master models 11, 12, 13, 14, 15, 16 are adjacent to each other. The master model 10 is manufactured by connecting the two via the connecting pin 9A and the pin hole 9B. Hereinafter, this manufacturing method will be described. Instead of this manufacturing method, six divided master models 11, 12, 13, 14, 15, and 16 may be manufactured at one time by one 3D printer 30, or A plurality of divided master models may be manufactured by one 3D printer 30.

[1] Structure of 3D printer 30 (schematic structure)
The 3D printer 30 used in the present embodiment is manufactured by Z Corp. (Zet Corporation).
The product name is “Zprinter 310 Plus System”.
The 3D printer 30 alternately repeats an operation of forming a powder layer on a first elevating plate 41 described later as a table and an operation of forming an adhesive layer of a predetermined shape on the powder layer. This is an apparatus for producing a three-dimensional object (in this embodiment, divided master models 11, 12, 13, 14, 15, 16) by laminating the powder layers and removing the powder not adhered by the adhesive layer.

  12 to 16 are schematic diagrams and operation diagrams of the 3D printer 30. FIG. As shown in each drawing, the 3D printer 30 supports a powder storage chamber 31 and a powder layer forming chamber 32, both of which are rectangular in cross section, in an apparatus frame 33 arranged side by side, and the powder storage chamber 31 has a first lifting plate. 41, a second elevating plate 42 (corresponding to a table) is provided in the powder layer forming chamber 32 so as to be driven up and down by elevating drive units 51 and 52, respectively. The first elevating plate 41 and the second elevating plate 42 move up and down at a constant pitch.

  Further, a pair of front and rear slide rails 34 extending in the left-right direction is provided on the upper portion of the apparatus frame 33, and a movable frame 35 that spans both the slide rails 34 and slides relative to the slide rail 34 is provided. In contrast, an ink jet print head 36 that slides in the longitudinal direction is provided, and a roller (not shown) along the longitudinal direction of the movable frame 35 is supported by the movable frame 35, and the lift drive units 51 and 52 and the movable frame 35 are supported. A control unit 38 is provided for controlling each unit such as the drive unit and the print head 36. The roller constitutes a powder layer forming portion (powder layer forming mechanism), and the print head 36 constitutes an adhesive layer forming portion (adhesive layer forming mechanism).

  The product name “Zprinter 310 Plus System” 3D printer is 1m30 cm in length in the left-right direction (length in the direction along the longitudinal direction of the slide rail 34), and is in the length direction in the front-rear direction (in the longitudinal direction of the movable frame 35). The length in the direction) is 50 cm and the height dimension is 1 m (both are approximate lengths), which is a considerably small device compared to a cutting machine such as an NC machine tool.

[2] Manufacturing method of divided master models 11, 12, 13, 14, 15, 16 (1) Before the 3D printer 30 is operated, slice data to be input to the control unit 38 of the 3D printer 30 is created in advance by the three-dimensional CAD 20 Keep it.
As shown in FIG. 11, a three-dimensional CAD 20 that is separate from the 3D printer 30 creates a three-dimensional model of the master model 10, and three-dimensional models of the divided master models 11, 12, 13, 14, 15, and 16. 21 is created, and the three-dimensional model 21 is sliced at a predetermined constant pitch to generate a large number of slice data (in the three-dimensional CAD 20) of a two-dimensional slice shape (also referred to as a circular slice shape). Keep it. The slicing direction is a direction (a direction other than this direction) corresponding to a direction (horizontal direction) along the front, rear, left and right of the seat cushion pad P. The slice surfaces are stacked in a direction corresponding to the vertical direction of the seat cushion pad P. A large number of horizontal lines lined up and down at regular intervals shown in FIG. 11 indicate slice planes (slice lines).

(2) Product name “ZP130Plaster” of US Z company as powder,
Product name “ZP58Binder” of Z company in the United States as an adhesive
Is used.
Then, the 3D printer 30 is operated according to the following procedures (2-1) to (2-7). As described above, each part of the 3D printer 30 operates under the control of the control unit 38.
(2-1) As shown in FIG. 12, a large amount of powder 39 is placed on the first lifting plate 41 of the powder storage chamber 31 with the first lifting plate 41 of the powder storage chamber 31 positioned at the lower stroke end. It is stored in. The second elevating plate 42 of the powder layer forming chamber 32 is located at the upper stroke end, and the movable frame 35 is located at the left stroke end. The upper end of the stored powder 39 is positioned slightly above the upper end of the powder storage chamber 31.

(2-2) As shown in FIGS. 12 and 13, the drive unit for driving the movable frame 35 is driven, and the movable frame 35 is integrated with the print head 36 toward the right stroke end. Move the slide up. Along with this sliding movement, a roller (not shown) pushes the upper end of the stored powder 39 on the first elevating plate 41 to the right, and the upper end of the stored powder 39 is moved to the second elevating plate 42 as shown in FIG. Spread thinly on top. The thickness of the powder layer 39S spread on the second elevating plate 42 is 0.08 mm. The thickness of the powder layer 39S is not limited to this value, and may be, for example, 0.089 mm to 0.203 mm.

(2-3) As shown in FIG. 14, the movable frame 35 positioned at the right stroke end slides on the slide rail 34 toward the left stroke end together with the print head 36. As shown in FIG. 15, along with this sliding movement, the print head 36 slides in the longitudinal direction of the movable frame 35, and the adhesive 43 is applied from the print head 36 onto the powder layer 39S, corresponding to the slice data. Inject to shape.
The sliding movement amount of the print head 36 in the longitudinal direction of the movable frame 35 and the timing of jetting the adhesive 43 from the print head 36 (spray time, jet time) are input to the control unit 38 of the 3D printer 30. The control unit 38 controls the slice data. When the injection of the adhesive 43 is finished, the second lifting plate 42 in the powder layer forming chamber 32 is lowered by a predetermined amount. The first elevating plate 41 of the powder storage chamber 31 is raised by a predetermined amount, and the upper end portion of the stored powder 39 is raised to a state shown in FIG.

(2-4) The movable frame 35 located at the left stroke end slides on the slide rail 34 integrally with the print head 36 toward the right stroke end and operates in the same manner as in the above (2-2). The upper end of the stored powder 39 on the first lifting plate 41 is pushed to the right, and the powder is spread again on the powder layer 39S and the adhesive layer 43 formed on the powder layer 39S. And it operates as in (2-3) above.

(2-5) The operations of the above (2-2) to (2-4) are repeated many times to stack a large number of powder layers 39S. Among the powder layers 39S, the layered bodies 39S1 (layered bodies 39S1 positioned with the adhesive layer 43 interposed therebetween), which are powder layer portions to which the adhesive layer 43 adheres, are connected via the adhesive layer 43.

(2-6) The powder 39 not adhered to the adhesive layer 43 is removed by suction with a suction device (not shown). As described above, the 3D printer 30 alternately repeats the formation operation of the powder layer 39S and the formation operation of the adhesive layer 43, and forms and stacks a plurality of layered bodies 39S1, thereby dividing the master models 11, 12, 13 , 14, 15, 16 are manufactured one by one.
That is, each slice data is input in advance to the control unit 38 of the 3D printer 30, and an adhesive layer 43 having a shape corresponding to each slice data is separately formed on each powder layer 39S. The layered bodies 39S1 positioned across 43 are connected by the adhesive layer 43 (see FIG. 16). In other words, each time the powder layer 39S is formed on the second elevating plate 42 in the powder layer forming part, the adhesive layer 43 having a shape corresponding to each slice data in the adhesive layer forming part one by one. The layered bodies 39S1 formed on the layer 39S and positioned with the adhesive layer 43 interposed therebetween are connected by the adhesive layer 43. With respect to the adhesive layer 43, first, the adhesive layer 43 having a shape corresponding to the lowermost slice data in FIG. 11 is formed, and the adhesive layer 43 having a shape corresponding to the upper slice data is sequentially formed. To go.

(2-7) The divided master models 11, 12, 13, 14, 15, and 16 are manufactured by sucking and removing the powder 39 that is not adhered to the adhesive layer 43. When removing the powder 39 not adhered to the adhesive layer 43, the powder 39 can be removed through the opening 18 of the divided portion 23 of the divided master model 11, 12, 13, 14, 15, 16. The powder 39 may be removed by a method other than suction. As described above, the layered body 39S corresponding to each slice data is formed by the 3D printer 30 and laminated to manufacture the divided master models 11, 12, 13, 14, 15, and 16.

  FIG. 10A shows the left opening 18 of the right front division master model 12, the left opening 18 of the right center division master model 14, and the left opening 18 of the right rear division master model 16. Although the powder 39 can be removed by suction from the opening 18, the powder 39 can also be removed by suction from the front or rear openings of these divided master models 12, 14, and 16.

  Similarly, the powder 39 can also be sucked and removed from the front and rear or left and right openings 18 of the left front divided master model 11, the left center divided master model 13, and the left rear divided master model 15. Thus, by sucking and removing the powder 39 to which the adhesive layer 43 is not adhered, the powder 39 can be efficiently and reliably removed in a short time, thereby improving workability. Can do.

(3) The split master models 11, 12, 13, 14, 15, 16 are manually coated with wax to prevent the split master models 11, 12, 13, 14, 15, 16 from cracking due to drying. Water may be applied instead of wax.

(4) After all of the plurality of divided master models 11, 12, 13, 14, 15, 16 are manufactured by the 3D printer 30, the plurality of divided master models 11, 12, 13, 14, 15, 16 are connected to each other. The pin 9A and the pin hole 9B are connected. In this way, the master model 10 is manufactured.

  For example, when the master model 10 is manufactured by cutting the outer surface of a hard resin material with an NC machine tool, chips are generated and the processing is troublesome, or the outer surface of the hard resin material is roughed and finished. Therefore, it takes a long time for the cutting process, and the process is expensive.

  On the other hand, according to the above-described means of the present invention, the 3D printer 30 that manufactures the master model 10 (the divided master models 11, 12, 13, 14, 15, 16) is an NC machine tool that is a cutting machine. Compared to a small machine, it can be installed without a large factory. In addition, since the 3D printer 30 is not a cutting machine, it does not generate chips and can save time and labor for processing chips, and can reduce processing time and improve workability. .

  If the master model 10 is solid, a large amount of powder is required, and the powder 39 is expensive and the manufacturing cost increases. However, according to the above-described means of the present invention, the divided master models 11, 12, 13, 14, 15 , 16 are hollow, and the powder 39 in the hollow portion 19 is removed through the opening 18, so that the powder 39 can be reused and the cost required for the powder 39 can be reduced. Further, as compared with the solid master model 10, the amount of the powder 39 constituting the master model 10 can be reduced and the master model 10 can be reduced in weight.

  Further, a plurality of divided master models 11, 12, 13, 14, 15, 16 are manufactured one by one by the 3D printer 30, and then a plurality of adjacent divided master models 11, 12, 13, 14, 15, 16 are used. Since the master model 10 is manufactured by connecting them via the pin 9A and the pin hole 9B, a smaller 3D printer 30 can be used as compared with the case of manufacturing the non-split type master model 10. As a result, even a large master model 10 can be manufactured.

  Since the master model 10 manufactured by connecting a plurality of divided master models 11, 12, 13, 14, 15, 16 is hollow, the weight of the master model 10 can be suppressed. 10 can be handled easily, the master model 10 can be easily handled in the manufacturing process of the mold 8, and the working efficiency can be improved.

[Another embodiment]
[1] As shown in FIGS. 17, 18 (a), 18 (b), 19 (a), 19 (b), and 19 (c), the divided master models 11, 12, 13, 14 are used. , 15, 16 may have a plurality of ribs 22 formed on the inner surface 19 </ b> A of the hollow portion 19. In the case of this embodiment, the plurality of ribs 22 are laid between the opposed inner surfaces 19A of the hollow portions 19 of the divided master models 11, 12, 13, 14, 15, 16, and the hollow portions 19 are formed into a plurality of portions. While partitioning into the hollow part 29, each hollow part 29 is divided into external space S (divided master models 11, 12,...) Through the openings 18 of the divided parts 23 of the divided master models 11, 12, 13, 14, 15, 16. 13, 14, 15, 16).

  According to this structure, since the rib 22 is constructed between the opposing inner surfaces 19A of the hollow portions 19 of the divided master models 11, 12, 13, 14, 15, 16, the divided master models 11, 12, 13, The strength and rigidity of 14, 15, and 16 can be increased, and the strength and rigidity of the master model 10 are the same as those of the first embodiment while being the hollow master model 10 (that is, the light master model 10). The structure can be stronger. As a result, deformation of the master model 10 can be avoided, and the master model 10 can be accurately formed in a target shape.

  Further, the hollow portion 19 is partitioned into a plurality of hollow portion portions 29, and each hollow portion portion 29 is separated from the external space via the opening 18 of the divided portion 23 of the divided master model 11, 12, 13, 14, 15, 16. Since it communicates with S, for example, it can be easily manufactured as compared with a structure in which a hollow portion sealed with one or two or more ribs 22 is formed. Furthermore, when removing the powder not adhered to the adhesive layer 43, the powder 39 can be removed through the openings 18 of the divided portions 23 of the divided master models 11, 12, 13, 14, 15, 16.

[2] As shown in FIG. 20, a plurality of ribs 22 are formed on the inner surface 19A of the hollow portion 19 of the divided master model 11, 12, 13, 14, 15, 16, and the plurality of ribs 22 are opposed to each other. The structure which is not constructed between inner surface 19A may be sufficient.

  According to this structure, since the plurality of ribs 22 are formed on the inner surface 19A of the hollow portion 19 of the divided master models 11, 12, 13, 14, 15, 16, the divided master models 11, 12, 13, 14, The strength and rigidity of 15, 16 can be increased, and the strength and rigidity of the master model 10 is the structure of the first embodiment while being the hollow master model 10 (that is, the light master model 10). Can be stronger. As a result, deformation of the master model 10 can be avoided, and the master model 10 can be accurately formed in a target shape.

[3] The numerical values given in this embodiment are merely examples, and may be different numerical values. For example, the number of divided master models 11, 12, 13, 14, 15, 16 may be other than six. Similarly, the number of connecting pins 9A and pin holes 9B may be other than the numbers shown in the drawings.

[4] As the powder or adhesive, a powder or adhesive other than the powder or adhesive mentioned in the above embodiment may be used. As the powder, for example, any one powder of gypsum, starch, plastic, and ceramic may be adopted.

[5] The present invention can also be applied to the production of the master model 10 of the mold 8 for the seat back pad, and the master model of the mold 8 for products other than the seat cushion pad P and the seat back pad. The present invention can also be applied to the case of manufacturing 10.

[6] The present invention is used in the case where the divided master models 11, 12, 13, 14, 15, 16 are manufactured using a 3D printer of a hot melt lamination method, which is a modeling technique for melting and laminating a resin. Can also be applied.

Perspective view of seat cushion pad Top view of seat cushion pad Bottom view of seat cushion pad Side view of seat cushion pad GG sectional view of FIG. 2A is a cross-sectional view taken along line AA in FIG. 2B is a cross-sectional view taken along line BB in FIG. 2C is a cross-sectional view taken along line CC in FIG. 2A is a sectional view taken along line DD in FIG. 2B is a sectional view taken along line EE in FIG. 2, and FIG. 2C is a sectional view taken along line FF in FIG. Plan view of the master model Exploded plan view of master model 8A is a cross-sectional view taken along the line A-D in FIG. 8B. FIG. 8C is a cross-sectional view taken along the line BB in FIG. The figure which shows the state which is making the slice section of the 3D model The figure which shows the action | operation (initial stage) of 3D printer (additive modeling apparatus) The figure which shows the action | operation (The state which is moving the powder layer) of 3D printer (lamination modeling apparatus) The figure which shows the action | operation (state in which the print head is located in the right stroke end) of 3D printer (additive modeling apparatus) The figure which shows the action | operation (state which has formed the adhesive bond layer) of 3D printer (lamination modeling apparatus) The figure which shows the action | operation (The state which has formed the adhesive bond layer in the uppermost layer part of a several powder layer) of 3D printer (lamination modeling apparatus) Plan view of the master model of another embodiment (A) is a BB view of FIG. 17 (b) is a DD view of FIG. 17A is a sectional view taken along line AA in FIG. 17B is a sectional view taken along line CC in FIG. 17C is a sectional view taken along line EE in FIG. It is a figure which shows 2nd another embodiment, (a) is a figure corresponding to the BB view of FIG. 17, (b) is a figure corresponding to the DD view of FIG. Longitudinal sectional view showing a mold formed by the master model manufactured in the present invention

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Side part 2 Center part 3 Recessed part 4 Groove 5 Slot 6 Wire 8 Mold 9 Connecting part 9A Pin 9B Pin hole 10 Master model 11 Split master model (left front split master model)
12 split master model (right front split master model)
13 Division master model (left center division master model)
14 Split master model (Right center split master model)
15 split master model (left rear split master model)
16 Split master model (Right-side split master model)
18 opening 19 hollow part 19A hollow part inner surface 20 CAD
21 Three-dimensional model 22 Rib 23 Dividing part 24 Lower mold 25 Upper mold 26 Cavity 29 Hollow part part 30 Modeling equipment (3D printer)
31 Powder storage chamber 32 Powder layer forming chamber 33 Device frame 34 Slide rail 35 Movable frame 36 Print head 38 Control unit 39 Powder 39S Powder layer 39S1 Powder layer portion (layered body)
41 First lifting plate 42 Table (second lifting plate)
43 Adhesive Layer 51 First Elevating Plate Elevating Drive 52 Second Elevating Elevating Drive L1 Vertical Dividing Line L2 Horizontal Dividing Line O Horizontal Axis P Seat Cushion Pad S External Space

Claims (7)

A master model for producing molds for solid products,
Forming the inside hollow,
A master model that is divided into a plurality of divided master models, and the divided master models are connected to each other through a connecting portion provided in the divided master model.   The master model according to claim 1, wherein one or more ribs are formed on the inner surface of the hollow portion of the divided master model.   The one or more ribs are laid between opposing inner surfaces of the hollow portion of the divided master model to partition the hollow portion into a plurality of hollow portion portions, and each hollow portion portion is divided into the divided master model. The master model according to claim 2, wherein the master model is communicated with an external space through an opening of the divided portion.   The master model according to any one of claims 1 to 3, wherein all of the plurality of divided master models are formed hollow. A method for producing a master model according to any one of claims 1 to 4,
Creating a three-dimensional model of the divided master model, and slicing the three-dimensional model at a predetermined pitch to create a plurality of slice-shaped slice data;
A layered body of a shape corresponding to each slice data is formed with a layered manufacturing apparatus and laminated to produce the divided master model,
The manufacturing method of the master model which manufactures the said master model by connecting the said some division | segmentation master models via the said connection part, after manufacturing the said some division | segmentation master model with the said additive manufacturing apparatus. The additive manufacturing apparatus is an apparatus that stacks a plurality of powder layers by alternately repeating an operation of forming a powder layer on a table and an operation of forming an adhesive layer on the powder layer,
An adhesive layer having a shape corresponding to each slice data is separately formed on each powder layer,
The powder layer portion to which the adhesive layer adheres is configured in the layered body, the layered bodies positioned with the adhesive layer sandwiched therebetween are connected by the adhesive layer, and the powder to which the adhesive layer is not bonded The master model manufacturing method according to claim 5, wherein the divided master model is manufactured by removing the master model.   The master model manufacturing method according to claim 5, wherein the solid product is a seat cushion pad or a seat back pad.

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