JP2010158736A - Porous thin article and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a porous thin article and its manufacturing method attaining that the durability and reliability of a device used for punching work are high, that a fine hole can be formed as compared with a punching machine, that the intrusion cross section (edge) of the fine hole becomes a right angle edge and a sharp punching shape is obtained not depending on the thickness of a work, that a crack is hardly generated even if a hole pitch is narrow, and that freedom of design as a product is high. <P>SOLUTION: Image data are prepared from the drawing visualized by a large number of extremely fine holes formed on the thin work, a punching pattern in which punching holes having different diameters and/or the same diameter are positioned is prepared based on the image data, and the extremely fine holes are formed at respective punching positions in the work according to the punching pattern by drills having diameters corresponding to the respective punching holes using an NC punching work machine. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a porous thin object in which a large number of extremely small holes are formed in a thin workpiece by a drill of an NC drilling machine and a method for manufacturing the same.

  A number of through holes are formed in a metal plate or a plastic plate, and there is a technique for visually expressing characters, designs, etc. by contrast between the through hole and the part where no through hole is formed. Panels are provided.

  As such a panel, for example, there is a punching plate in which a large number of through holes are formed in a plate material by a punching machine (see, for example, Patent Document 1).

  Further, there is a panel drilling method for forming a hole in a panel using a punching machine (see, for example, Patent Document 2).

JP-A-6-315729 Japanese Patent Laid-Open No. 8-168993

However, since the conventional panels (plates) employing the above technique, including the above-mentioned Patent Documents 1 and 2, are manufactured using a punching machine, there are the following problems a to d.
a) The die pin of the punching machine has no pressure resistance, is likely to be broken or chipped, and it is difficult to maintain the shape of the die pin.
b) Because of the problem a, the thin workpiece (film, thin plate, etc.) has a thickness of about 0.1 mm or less, and the minimum hole diameter is about 0.35 mm. In view of this, when trying to drill holes by molding, the thickness of the workpiece can be increased, but the hole diameter is limited to about 0.5 mm at the minimum. That is, it becomes impossible to form fine holes as compared with the punching machine.
c) In perforation using punching (and laser processing), the intrusion cross section (edge) of the hole is rounded and a right-angled edge cannot be formed. If the thickness of the workpiece increases, the edge becomes more rounded and a sharp perforated shape cannot be obtained. Moreover, in the drilling by etching, the workpiece is limited to a metal sheet, and a plastic film cannot be drilled in the first place.
d) In punching by punching, if the interval between adjacent holes (hole pitch) is narrow, cracks may occur depending on the material of the workpiece due to the pressing force during pressing. In particular, in order to increase the expressiveness of the design so that the panel is used for decoration, it is required to make the hole pitch as small as possible. On the other hand, in order to prevent the occurrence of cracks, a sufficient hole pitch is required, which not only causes problems on the product, but also limits the freedom of design.

  For example, Patent Document 1 describes that a hole having at least two types of sizes is formed at appropriate positions, and a decorative pattern is expressed by the density of the hole and a blank portion where the hole is not formed. However, in the gray scale expression method using the large and small diameter holes arranged on the XY axis, in particular, when drawing a photographic image or the like in 256 gradations, a rough drawing in which the voids are conspicuous in the dark portion (substantially) The resolution becomes worse, and the expressiveness of the holes is reduced.

This invention was made paying attention to such various problems a to d,
1) The durability and reliability of the equipment used for drilling is high.
2) Capable of forming extremely small holes as compared to punching machines.
3) The entry cross section (edge) of the micro hole is a right-angled edge, and a sharp drilling shape can be obtained regardless of the thickness of the workpiece.
4) Even if the hole pitch is narrow, cracks are unlikely to occur, and the product has a high degree of design freedom.
An object of the present invention is to provide a porous thin material and a method for producing the same.

  In order to solve the above-described problems, the porous thin object of the present invention is characterized in that a number of extremely small holes are formed in a thin workpiece by a drill of an NC drilling machine. More specifically, the porous thin material is formed by arranging micropores with different diameters and / or micropores with the same diameter in accordance with a desired pattern.

  In the present invention, it is a great feature that an extremely small hole is formed by using an NC drilling machine. As an NC drilling machine, a high-speed NC drilling machine having a multi-axis (for example, three axes) spindle is used. Machine is preferred. This high-speed NC drilling machine is capable of drilling at high speed and high feed rate, and has a mechanism that can drill multiple workpieces (stacked multiple workpieces) at the same time using spindles of other axes. Equipped with a capability that, for example, drilling of 300 holes or more per minute can be realized. In addition, the high-speed NC drilling machine can handle workpiece heights of up to about 5 mm, and it is easy to punch multiple layers at once, for example, as a workpiece, making it suitable for mass production processing. ing.

  Specifically, the drill shank diameter of the NC drilling machine is 3.175 mm or less, and the tip diameter is 0.05 to 0.4 mm. Regarding the shank diameter of the drill, when a high-speed NC drilling machine is used, the straight running performance of the drilling is exhibited to the maximum when the shank diameter is 3.175 mm or less. Further, as described in the above problem b, in the drilling by the punching machine, the hole diameter is limited to about 0.35 mm at the minimum, but according to the drill of the NC drilling machine, it is 0.05 to 0.4 mm. It becomes possible to form a small hole having a diameter.

  The thin workpiece to be drilled with such a very small diameter drill is any one of a resin film, a resin thin plate, and a metal thin plate. The thin plate includes a sheet. Of course, the porous thin material produced from the thin workpiece is in the form of a film, a thin plate, a sheet or the like.

  In the method for producing a porous thin object of the present invention, image data is created from a drawing to be visualized by a large number of extremely small holes formed in a thin workpiece, and different diameters and / or on the basis of the image data. Create a drilling pattern in which drills with the same diameter are positioned, and use an NC drilling machine to drill a hole with a diameter corresponding to each drilling to form a micro hole at each drilling position in the workpiece according to the drilling pattern. It is characterized by.

  Here, the drawings are not limited to characters (kanji, hiragana, katakana, numbers, English characters, etc.), landscape paintings, portraits, animals and plants, geometric patterns, etc., and may be photographs or paintings.

  Also in this manufacturing method, similarly to the above, the shank diameter of the drill is 3.175 mm or less, and the tip diameter is 0.05 to 0.4 mm. The thin workpiece is any one of a resin film, a resin thin plate, and a metal thin plate.

  In particular, when the thin workpiece is a resin film, a plurality of laminated resin films (workpieces) are placed on the auxiliary material placed on the table of the NC drilling machine, and the secondary resin film is placed on the uppermost resin film. It is preferable to place a material and form a very small hole in the work by a drill from the auxiliary material.

  As the auxiliary material, a bakelite board is exemplified as the one to be placed on the table of the NC drilling machine (backup board), and as a material to be placed on the workpiece (for example, on the uppermost resin film), a water-based lubricant or the like is used. An entry sheet (for example, an aluminum sheet with a lubricant) coated with is used.

According to invention of Claim 1, 5, the following effect is acquired.
(1) Minimal holes can be formed more easily than punching by a punching machine or molding.
(2) The durability and reliability of the device used for drilling (NC drilling machine) is high.
(3) The entry cross section (edge) of the micro hole becomes a right-angled edge, and a sharp drilling shape can be obtained regardless of the thickness of the workpiece.
(4) Even if the pitch of the very small holes is narrow, cracks are hardly generated, and the degree of freedom of design as a product is high.
(5) According to the above (1) to (4), a large number of different diameters and / or minute holes having the same diameter can be densely arranged. The ability to express drawings with (small pores) is increased (high definition is possible), and it is possible to provide a porous thin product with higher design.

  According to the third and sixth aspects of the invention, it is possible to form a very small hole having a diameter of 0.05 to 0.4 mm, as compared with a punching machine or punching by molding.

  According to invention of Claim 8, even if a to-be-processed object is a thinner resin film, a hole burr | flash can be suppressed more effectively.

It is a schematic flowchart which shows the process about the manufacturing method which produces the porous thin material of this invention. It is a figure for demonstrating the triaxial arrangement | sequence of the drilling of ST2 in the flowchart of FIG. 1 is a schematic enlarged view showing a state when a micro hole is formed in a work (a laminate of a plurality of resin films) using an NC punching machine used in the film punching process of ST4 in the flow diagram of FIG. It is sectional drawing. It is a figure (a) and (b) which show an example of the porous thin thing of the present invention. It is figure (a), (b), (c) which shows another example of the porous thin material of this invention. It is a figure which shows the example of application of the porous thin-shaped object of this invention. It is a figure which shows another example of application of the porous thin material of this invention.

  Hereinafter, the present invention will be described in more detail with reference to embodiments.

  As described above, the present invention is characterized by drilling a thin workpiece using an NC drilling machine, and a porous thin product is produced using the NC drilling machine. The manufacturing method to be described will be described with reference to the schematic flow chart of FIG.

  However, in the flowchart of FIG. 1, a high-speed NC drilling machine having a multi-axis (for example, three axes) spindle is used as the NC drilling machine, and the thin workpiece is a resin film.

  First, in step ST1, image data is created from a drawing (design, image) to be visualized by a large number of extremely small holes formed in the thin workpiece. That is, as a drawing, for example, a dog (photograph) shown in FIG. 4 (a), a mesh pattern for a speaker network of a cellular phone shown in FIG. 4 (b), a gradation pattern shown in FIG. (B), quadrangle (c)] and the like are read by a scanner or the like, and the read image information is binarized or converted to 256 gray scales.

  In steps ST2 and ST3, a perforation pattern in which perforations having different diameters and / or same diameters are formed based on binary or 256 gray scale image data. More specifically, in step ST2, the size of the perforation diameter (minimum hole diameter), the pitch of the perforations (minimum hole), the pitch of the perforations, based on the binary or 256 gray scale image data. CAD edit the 3-axis array.

  As shown in FIG. 2, the triaxial arrangement here includes an A axis and a B axis having an inclination of 60 ° with respect to the longitudinal Y axis, and a plane formed by the three axes of the Y axis, the A axis, and the B axis. Is divided into six equal parts, and perforation is performed for each divided area.

  In step ST3, after allocating the size of the drilling holes, editing the CAD of the three-axis array of drillings (after creating the drilling pattern), converting to XY coordinate values as drilling position information, a machine that can be recognized by a high-speed NC drilling machine A control code is assigned and converted to NC data (numerical control data conversion, CAD editing).

  In step ST4, a very small hole is formed at each drilling position in the workpiece (resin film) according to the drilling pattern by a drill having a diameter corresponding to each drilling using a high-speed NC drilling machine.

  A method for punching a resin film is shown in FIG. However, FIG. 3 shows only one axis. In FIG. 3, a drill 30 having a predetermined diameter is attached to the tip of a spindle 20 of a high-speed NC drilling machine. As described above, the shank diameter of the drill (including the drill 30) used for drilling is 3.175 mm or less, and the tip diameter is 0.05 to 0.4 mm. A work retainer 22 having a protrusion 23 is attached to the tip of a cylindrical work retainer support portion 21 disposed around the spindle 20, and the work 2 is moved downward by the work retainer 22 (protrusion 23) during drilling. Press. The tip diameter of the drill is 0.05 to 0.4 mm. Within this range, a drill with a standard diameter may be used, or a drill with a nonstandard diameter may be used. Appropriate selection may be made according to the above.

  Here, five resin films are laminated on the resin film 1 as a workpiece, and the five resin films 1 are punched at a time as a laminated workpiece 2. The work 2 is placed on a bakelite 41 as a secondary material placed on the table 10 of the high-speed NC drilling machine, and an entry sheet 42 is placed on the work 2 (the uppermost resin film 1) as another secondary material. . Then, a very small hole is formed in the workpiece 2 by the drill 30 from above the entry sheet 42 while being pressed by the workpiece presser 22 with respect to the workpiece 2 sandwiched between the bakelite 41 and the entry sheet 42.

  At the time of drilling, based on the numerical data of the XY coordinates of the drilling, first, drill holes with a predetermined diameter are formed in order, and then all corresponding holes are replaced with another drill with a predetermined diameter. The formation of extremely small holes in diameter is repeated in order, and the workpiece 2 is subjected to drilling with all the predetermined diameter drills.

  At the time of drilling, pressure is applied from above the entry sheet 42 by the work holder 22 (projection 23), and the auxiliary materials 41, 42 and the work 2 are pressed against the table 10, thereby improving the adhesion of the work 2 and drill cutting. The effect of discharging the cutting powder at the time from the spiral groove of the drill to the upper part can be enhanced, and voids between the resin films 1 in the workpiece 2 can be eliminated to effectively suppress the generation of hole burrs.

  Further, when the entry sheet 42 is used as the auxiliary material on the workpiece 2 at the time of drilling, the drilling can be performed while being dry. This dry processing increases the efficiency of the commercialization process because the workpiece after drilling does not require cleaning. Moreover, if the entry sheet 42 is used, not only a resin film but also a soft workpiece such as a resin thin plate can be drilled with good quality. That is, the hole position is excellent, there is no hole burr, and there is no hole burning.

  FIG. 3 shows only one axis of a high-speed NC drilling machine. For example, if three axes are used, it is possible to punch 5 resin films × 3 axes = 15 resin films at a time. Yes, mass production is possible.

  In step ST5, the resin film 1 after perforation is cut to a required size (excluding the outer shape), and an adhesive tape, for example, is attached to the back surface of the resin film after cutting so that the resin film can be attached to an object. And commercialize resin films.

  According to the above manufacturing method, since a large number of small holes are formed in a thin workpiece by a drill of an NC drilling machine, it is possible to form a small hole more easily than a punching machine or drilling by molding. Become. Moreover, the machine used for drilling is an NC drilling machine, which has high durability and reliability. Further, since drilling is performed by a drill of an NC drilling machine, the entry cross section (edge) of the extremely small hole becomes a right-angled edge, and a sharp drilling shape can be obtained regardless of the thickness of the workpiece. Moreover, even if the micro hole pitch is narrow, cracks hardly occur and the product has a high degree of design freedom.

  Because of these effects, it is possible to densely arrange a large number of micropores with different diameters and / or the same diameter, so that the drawing of a drawing by a microhole and a portion where a micropore is not formed (non-minimal pore portion) The expressive power is increased (high definition is possible), and it is possible to provide a porous thin material with higher design.

  As a specific example of the porous thin object, as shown in FIG. 4 (a), as a drawing, a photo image of “dog” is formed on a thin work piece (resin thin plate, metal thin plate). Not only can it be visualized as a decorative panel with a diameter and a very small hole of the same diameter, but it can also provide a speaker network for a mobile phone made of a resin film as shown in FIG. 4 (b). is there〕.

  In addition, a strip-like gradation is formed in parallel by forming a small hole whose diameter gradually changes as shown in FIG. 5A on a resin thin plate or metal thin plate, and the same diameter or sequentially changes as shown in FIG. 5B. A circular gradation can be created by forming a minimal hole with a radial diameter in a radial shape, and a rectangular gradation can be created by forming a minimal hole with a different diameter in a square annular shape as shown in FIG. it can.

  As an application example of the porous thin object, for example, as shown in FIG. 6, it is used as a speaker network 51 of a mobile phone 50, or as shown in FIG. 7, an audio device (external speaker) 70 for a mobile terminal 60 is used. It can be used as the speaker network 71 of

  In addition, when using an NC drilling machine, in order to improve the quality of drilling (minimal hole) shape, by controlling the tip angle, groove twist angle, and groove width of the drill, A suitable drill shape is prepared, cutting waste is increased, generation of cutting heat is suppressed, and in particular, melting and shape collapse of a resin film due to drilling heat can be prevented.

  Furthermore, by setting the aspect ratio between the drill diameter and the workpiece thickness to be within 1:10, it becomes easier to obtain a sharp drilling shape in which the entry cross section (edge) of the minimal hole is a right-angled edge. Moreover, even if the micro hole pitch is narrow (0.1 mm), cracks are difficult to occur.

1 Resin film (thin workpiece)
2 Work 10 Table 20 Spindle 21 Work holding support 22 Work holding 30 Drill 41 Bakelite (sub-material)
42 Entry sheet (auxiliary material)

Claims (8)

  A porous thin object characterized by forming a large number of extremely small holes in a thin workpiece by a drill of an NC drilling machine.   2. The porous thin article according to claim 1, wherein the micropores with different diameters and / or the micropores with the same diameter are arranged in accordance with a desired pattern.   The porous thin article according to claim 1 or 2, wherein the drill has a shank diameter of 3.175 mm or less and a tip diameter of 0.05 to 0.4 mm.   4. The porous thin object according to claim 1, wherein the thin workpiece is a resin film, a resin thin plate, or a metal thin plate.   Create image data from a drawing to be visualized by a number of extremely small holes formed in a thin workpiece, create a drilling pattern in which perforations of different diameter and / or same diameter are positioned based on this image data, and NC A method for producing a porous thin object, wherein a minimum hole is formed at each drilling position in a workpiece according to a drilling pattern by a drill having a diameter corresponding to each drilling using a drilling machine.   6. The method for producing a porous thin article according to claim 5, wherein the drill has a shank diameter of 3.175 mm or less and a tip diameter of 0.05 to 0.4 mm.   The method for producing a porous thin object according to claim 5 or 6, wherein the thin workpiece is any one of a resin film, a resin thin plate, and a metal thin plate.   The thin workpiece is a resin film, and a plurality of laminated resin films (workpieces) are placed on the auxiliary material placed on the table of the NC drilling machine, and the auxiliary material is placed on the uppermost resin film. The method for producing a porous thin article according to claim 7, wherein a minimal hole is formed in the work by a drill from above the auxiliary material.

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