JP2018079652A - Resin molding apparatus and resin molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin molding apparatus and a resin molding method capable of employing all thermoplastic resins by use of a resin mold formed by three-dimensional modeling, and by injecting a resin material for product into the resin mold.SOLUTION: The resin molding apparatus has: a stage; a storage vessel installed on the stage; an energy ray irradiation part emitting an energy ray; an injection part plasticizing a first material being a synthetic resin and injecting the same from an injection port; and driving means that enables the stage, the energy ray irradiation part and the injection part to move relatively three-dimensionally. The storage vessel has a table inside drivable in at least the gravity direction and is stored with a liquid second material including an energy ray curable resin cured by the energy ray.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a resin molding apparatus and a resin molding method.

  Conventionally, there has been known a method for obtaining a desired three-dimensional molded article by using an ultraviolet curable resin for forming a three-dimensional molded article and sequentially laminating cured layers cured in layers by ultraviolet rays (Patent Document 1). Patent Document 1 discloses that a dummy hardened layer is formed in advance in a continuous manner under the branch when forming a branch that does not reach the lower end of the three-dimensional molded product. It is said that an accurate three-dimensional molded product can be obtained.

  However, in the method of obtaining the three-dimensional molded product disclosed in Patent Document 1, it is necessary to add a portion corresponding to the dummy hardened layer from the design stage, and further, after the three-dimensional molding, the dummy mold is used. It is necessary to remove the cured product. Therefore, a hot melt type ink containing different types of resin materials having different melting points is ejected from an inkjet head, and a desired three-dimensional molded product formed of a high melting point ink and a desired three-dimensional shape of a low melting point ink. A method is disclosed in which a single layer in a region other than a molded product is formed, and the single layer is laminated to form a solid (Patent Document 2).

  In the method disclosed in Patent Document 2, the low melting point ink is melted and removed from the formed solid by heating at a temperature higher than the melting point of the low melting point ink and lower than the melting point of the high melting point ink. By doing so, it is possible to obtain a desired three-dimensional molded product formed of a high melting point ink.

JP-A-2-251419 JP-A-9-123290

  In the formation method of the three-dimensional molded product disclosed in Patent Document 1 and Patent Document 2, there are limitations on materials that can be applied. In Patent Document 1, a material that can be cured by an energy beam including ultraviolet rays must be used. In Patent Document 2, a hot melt type ink is required to be a resin material that can be discharged and supplied from an inkjet head.

  However, in recent years, modeling of a three-dimensional molded product (hereinafter referred to as 3D modeling) is not limited to modeling of a desired shape, and a three-dimensional molded product obtained by 3D modeling such as desired quality, such as strength, heat resistance, and chemical resistance. It has come to be required. Therefore, the method for forming a three-dimensional molded product disclosed in Patent Document 1 and Patent Document 2 is applied to a prototype or a product that requires a material that cannot be cured by an energy beam or an extremely low melting point material. It was difficult to do.

  Accordingly, there are provided a resin mold by 3D modeling and a resin molding apparatus and a resin molding method capable of using any thermoplastic resin by injecting a product resin material into the resin mold.

  SUMMARY An advantage of some aspects of the invention is to solve at least a part of the problems described above, and the invention can be implemented as the following forms or application examples.

  Application Example 1 A resin molding apparatus according to this application example plasticizes a stage, a storage tank installed on the stage, an energy beam irradiation unit that irradiates energy rays, and a first material that is a synthetic resin. , An injection unit that injects from the injection port, the stage, and the driving means that enables the energy beam irradiation unit and the injection unit to relatively move three-dimensionally, and the storage tank is at least in the direction of gravity And a liquid second material containing an energy beam curable resin that is cured by the energy beam is stored therein.

  According to the resin molding apparatus of this application example, an energy beam irradiating unit that cures an energy beam curable resin that is easy for three-dimensional modeling, so-called 3D modeling, by energy beam irradiation, and an injection unit that can inject a thermoplastic resin , A mold capable of injection molding of a thermoplastic resin can be formed by 3D modeling by irradiating an energy ray curable resin with an energy ray and cured, and mold design, mold production, mold The lead time from assembly mold manufacturing to product injection molding can be set shorter than before. Thereby, the high functional resin material which cannot be applied to the energy beam curable resin can be molded in a short time and can be reduced in cost by not creating an expensive metal mold.

  Application Example 2 In the application example described above, the energy beam irradiated from the energy beam irradiation unit hardens the second material to form a first molded product in a layered form, and is injected from the injection unit. The first material is cured, a second molded product is formed in layers, the first molded product is laminated in the direction of gravity, and the second molded product is laminated in the direction of gravity. A second molded body is formed.

  According to the application example described above, it is possible to easily obtain the first molded body and the second molded body that are 3D-modeled.

  Application Example 3 In the application example described above, the first molded body is formed with a cavity for forming the second molded body, and the second molded body has the second material directed toward the cavity. Injected and filled.

  According to the application example described above, the first molded body can be used as a mold, and the second material can be injection-molded into the cavity formed in the first molded body. The lead time from mold manufacture for mold assembly to product injection molding can be set shorter than before. Thereby, the high functional resin material which cannot be applied to the energy beam curable resin can be molded in a short time and can be reduced in cost by not creating an expensive metal mold.

  Application Example 4 In the application example described above, the energy ray is ultraviolet light.

  According to the above-mentioned application example, since it is a low calorific energy ray with a high productivity due to a short curing time and a small calorific value of the irradiation part and ultraviolet rays, the thermal influence on the second material constituting the second molded product. Can be avoided.

  Application Example 5 In the application example described above, the synthetic resin is a thermoplastic resin.

  According to the application example described above, precise modeling by injection molding becomes possible.

  [Application Example 6] In the resin molding method of this application example, an energy beam is irradiated onto a liquid second material containing an energy beam curable resin stored in a storage tank installed on a stage, and the energy beam curable type is applied. Mold molding single layer forming step of curing the resin to form a single layer mold molding single layer, and molding of the first material, which is a plasticized synthetic resin, into the mold molding single layer A single layer injection molding process for forming a single molding layer by injection from the injection part toward the region and laminating the first molding single layer formed by the mold molding single layer forming step. , A mold molding layer forming step for forming a second mold molding single layer by the mold molding single layer forming step, and a first molding single layer formed by the single layer injection molding step, Molded product lamination that forms a second molded product single layer by a single-layer injection molding process And repeating the mold molding lamination process a predetermined number of times, the mold molding single layer having a predetermined number of layers, and a laminated mold molded body, and the molding lamination process the predetermined number of times, And repeatedly forming a molded body laminated on the molding region of the mold molded body.

  According to the resin molding method of this application example, the thermoplastic resin is injected and laminated on the molded body obtained by curing and laminating the energy ray curable resin that is easy to 3D modeling by energy ray irradiation. Thus, a molded body can be obtained, and the lead time from mold manufacturing, mold manufacturing and mold assembly to mold injection molding can be set shorter than before. Therefore, a high-performance resin material that cannot be applied to the energy beam curable resin can be made in a short time and a resin molding method capable of reducing the cost by not creating an expensive metal mold.

  Application Example 7 In the application example described above, the method includes a mold release step of releasing the molded body from the mold molded body, and the mold release step dissolves the mold molded body.

  According to the application example described above, the molded body can be released from the molded body without being damaged.

  Application Example 8 In the application example described above, the energy beam is ultraviolet light.

  According to the application example described above, it is possible to avoid the thermal influence on the molded body because of the high productivity due to the short curing time and the low calorific energy rays with a small calorific value of the irradiated part and ultraviolet rays.

  Application Example 9 In the application example described above, the synthetic resin is a thermoplastic resin.

  According to the application example described above, precise modeling by injection molding becomes possible.

The block diagram which shows schematic structure of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The flowchart of the resin molding method which concerns on 2nd Embodiment. The external appearance perspective view which shows the 2nd molded object illustrated in the resin molding method which concerns on 2nd Embodiment. The detailed flowchart of the molded object single layer molding process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The detailed flowchart of the single layer injection molding process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The A section enlarged view shown in FIG. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment.

  Embodiments according to the present invention will be described below with reference to the drawings.

(First embodiment)
FIG. 1 is a configuration diagram showing a schematic configuration of a resin molding apparatus according to the first embodiment. A resin molding apparatus 1000 shown in FIG. 1 includes a stage 200 and a liquid resin material Mf as a liquid second material that includes an energy ray curable resin that is installed on the stage 200 and is cured by being irradiated with energy rays. A storage tank 300 in which a storage space 300a to be stored is formed, and a base 100 including a stage driving device as a driving unit (not shown) that three-dimensionally drives the stage 200 are provided. The three-dimensional drive is capable of driving in any of the X, Y, and Z directions shown in the figure.

  In the storage space 300a of the storage tank 300, a molding unit 400 including a table 410 having a molded product formation surface 410a (hereinafter referred to as a formation surface 410a) and a drive shaft 420 that drives the table 410 in the Z-axis direction. Has been placed.

  As described above, in the resin molding apparatus 1000, the liquid resin material Mf containing the energy beam curable resin as the second material is stored in the storage tank 300, and is formed on the formation surface 410a by the energy beam as described later. Since it is an apparatus for curing, forming a cured layer, and laminating, the liquid upper surface of the liquid resin material Mf and the formation surface 410a are arranged substantially in parallel. Therefore, it can be said that the Z-axis direction shown in the drawing is a so-called gravity direction, and the table 410 is driven in the gravity direction.

  An energy ray irradiating unit 500 that irradiates energy rays toward the liquid upper surface of the liquid resin material Mf is disposed at the upper part in the gravity direction of the storage tank 300. Note that the resin molding apparatus 1000 according to the present embodiment will be described by exemplifying ultraviolet rays as energy rays. Therefore, the energy beam irradiation unit 500 will be described as the ultraviolet irradiation unit 500 below. In addition, as an energy ray, it is not limited to an ultraviolet-ray, High frequency, a radiation, The energy ray and energy-beam curable resin which provide the energy which hardens | cures to-be-irradiated object may be sufficient.

  In addition, an injection unit 600 that plasticizes and injects a resin material Mp as a first material, which is a synthetic resin, which is a product material, is disposed at the upper part in the gravity direction of the storage tank 300. In this embodiment, an injection unit 600 including a flat screw will be described as an example.

  The injection unit 600 includes a heater (heating means) (not shown), and has a cylinder 620 having an internal space, a flat screw 630 disposed in the internal space of the cylinder 620, and a driving device 640 that rotationally drives at least the flat screw 630. , And a material supply unit 610 that supplies the pellet-shaped resin material Mp to the internal space of the cylinder 620.

  The pellet-shaped resin material Mp supplied to the cylinder 620 is heated to a temperature equal to or higher than the glass transition point by a heater provided in the cylinder 620 to become a plasticized resin material Mp. The plasticized resin material Mp is sent to the injection port 620b by rotating the flat screw 630, and is injected from the injection port 620b.

  The principle of injection of the resin material Mp by the flat screw 630 is that the pellet-shaped resin material Mp is conveyed from the material supply unit 610 to the material charging port 620a of the cylinder 620 and plasticized by the heater of the cylinder 620. The plasticized resin material Mp is formed in a spiral shape from the outside of the flat screw 630 toward the rotation center 630r when the flat screw 630 is rotated around the rotation center 630r by the driving device 640. The plasticized resin material Mp is conveyed under pressure toward the rotation center 630r along the conveyance groove 630a, and is injected from the injection port 620b by the pressure.

  The resin molding apparatus 1000 according to this embodiment includes a control unit 700, a stage controller 710 that controls driving of a stage driving device (not shown) provided in the base 100, and molding that is driven in the direction of gravity in the storage tank 300. A table controller 720 that controls a table driving device (not shown) that drives the unit 400, an ultraviolet irradiation control unit 730 that controls the ultraviolet irradiation unit 500, and an injection control unit 740 that controls the injection unit 600 are controlled.

  2 to 5 are views for explaining the driving of the resin molding apparatus 1000. FIG. FIG. 2 is a schematic configuration diagram showing a preparation stage for resin molding by the resin molding apparatus 1000. As shown in FIG. 2, in the resin molding preparation stage of the resin molding apparatus 1000, the liquid resin material Mf in which a cured product is generated by irradiating the storage space 300 a of the storage tank 300 with ultraviolet rays UV as energy rays is generated. Store.

Then, the formation surface 410a of the table 410 is submerged in a depth D _L1 from the liquid surface Sf of the stored liquid resin material Mf. The depth D _L1 is the amount of sinking of the table 410 required to obtain the thickness of the first layer of the molded product to be described later.

  In the injection unit 600, the pellet-shaped resin material Mp is charged from the hopper 610 a of the material supply unit 610 and conveyed to the cylinder 620. In the cylinder 620, the resin material Mp is heated to a temperature exceeding the glass transition point by a heater (not shown) and plasticized. The resin material Mp plasticized by the rotation of the flat screw 630 is pressurized and conveyed to the injection port 620b.

When preparation for resin molding of the resin molding apparatus 1000 shown in FIG. 2 is completed, ultraviolet rays UV as energy rays are emitted from the ultraviolet irradiation port of the ultraviolet irradiation unit 500 toward the liquid surface Sf of the liquid resin material Mf as shown in FIG. Is irradiated. The stage 200 is driven in the XY direction relative to the ultraviolet irradiation unit 500 by a stage driving device (not shown) provided in the base 100 in synchronization with the irradiation of the ultraviolet UV, and is stored in the stage 200. 300 is moved in the XY direction relative to the ultraviolet irradiation unit 500. The liquid resin material Mf is cured by being irradiated with ultraviolet rays UV, and a first molding die layer 801 as a first molded first layer having a thickness of D _L1 is formed on the formation surface 410a. The

  The resin material Mp plasticized from the injection port 620b of the injection unit 600 is injected into a predetermined injection region as shown in FIG. 4 in the molding region 801s surrounded by the first mold layer 801 described in FIG. A first molded layer 901 as the first molded second layer is formed on the forming surface 410a. In this example, the form in which the first molding layer 901 is formed is illustrated with the inside of the first molding die layer 801 formed in a frame shape as the first molding region 801s.

  As described above, the liquid resin material Mf is cured by ultraviolet UV to form the first mold layer 801, and the resin material Mp plasticized using the first mold layer 801 as a mold frame is injected from the injection unit 600. By forming the first molded layer 901, a layered molded product is formed. Then, by repeating the formation of the layered product, the molded product is formed on the forming surface 410a of the table 410 as shown in FIG.

  FIG. 5 shows a state in which the formation of the layered product described above is repeated and laminated. As shown in FIG. 5, a second second mold layer 802 is laminated on the first first mold layer 801. In this embodiment, a cup-like shape with the first molded layer 901 of the second molded body 900 described later as the bottom is illustrated. In the second mold layer 802 of the second layer, the second mold outer mold layer 802a is laminated on the upper surface of the first mold layer 801 so as to constitute a second mold region 802s that forms the second mold layer 902. Then, the second molded inner mold layer 802b is laminated on the upper surface of the first molded layer 901. Then, the resin material Mp is injected into the second layer molding region 802 s to form the second molding layer 902.

  Next, a third molded outer mold layer 803a is laminated on the upper surface of the second molded outer mold layer 802a so as to form a third molded region 803s forming the third molded layer 903, and the third molded inner mold layer is formed. 803b is laminated on the upper surface of the second molding inner mold layer 802b to form a third molding mold layer 803 as the third layer. Then, the resin material Mp is injected into the third-layer molding region 803 s to form the third molding layer 903.

  Further, the N-th N-th mold layer 80N and the N-th mold layer 90N are sequentially stacked on the third-layer third mold layer 803 and the third mold layer 903, and the first molded body 800, The second molding 900 is formed by filling a molding region formed by the one molding 800, that is, a so-called cavity, with the resin material Mp.

  As described above, the first molded body 800 is a molding resin mold in which a cavity that is a space for molding the second molded body 900 is formed. Therefore, it is not necessary to prepare an expensive metal mold for manufacturing the second molded body 900 as a product, that is, a so-called mold, and the liquid resin material Mf is easily cured by ultraviolet rays UV as energy rays. Solid modeling, so-called 3D modeling, is possible. Further, the second molded body 900 as a product can be formed by so-called injection molding in which a resin material Mp of a thermoplastic resin is injected from the injection part 600 and the first molded body 800 is molded as a molding die. Therefore, the resin material Mp may be a thermoplastic resin. This is because, conventionally, in a modeling apparatus that generally performs 3D modeling using an ultraviolet curable resin, the resin material of the product is limited to the ultraviolet curable resin. In other words, if a resin that cannot be cured by ultraviolet rays is designated as the product resin, it is necessary to rely on injection molding using a mold.

  According to the resin molding apparatus 1000 according to the present embodiment, it is possible to mold a mold for injection molding of a thermoplastic resin with an energy ray curable resin capable of 3D modeling in a short time and at a low cost. Therefore, it is possible to perform resin molding that can reduce the cost by using a high-functional resin material that cannot be applied to the energy beam curable resin in a short time and without creating an expensive metal mold.

  Examples of the ultraviolet curable resin include acrylate radical polymerization and epoxy cation polymerization, and it can be said that resins other than this resin material are incompatible with molding by ultraviolet curing. Examples of the thermoplastic resin material that can be applied to the second molded body 900 that is a product include, as a crystalline resin, Pe (polyethylene), PP (polypropylene), PA (polyamide), POM (polyacetal), PBT (polybutylene terephthalate). ), PPS (polyphenylene sulfide), PEEK (polyether ether ketone) and the like. An example of the liquid crystalline resin is LCP (Liquid Crystal Polymer). Examples of the amorphous resin include PS (polystyrene), ABS, PMMA (acrylic), PC (polycarbonate), PPE (polyphenylene ether), and the like.

  The resin molding apparatus 1000 described above is an apparatus that allows the ultraviolet irradiation unit 500 and the injection unit 600 to relatively move three-dimensionally with respect to the molding unit 400 by a stage driving device (not shown) of the stage 200 provided in the base 100. However, it is not limited to this. For example, an apparatus may be used in which the ultraviolet irradiation unit 500 and the injection unit 600 are held by a robot arm and are relatively three-dimensionally driven with respect to the molding unit 400.

(Second Embodiment)
As a second embodiment, a resin molding method using the resin molding apparatus 1000 according to the first embodiment will be described. FIG. 6 is a flowchart of the resin molding method according to the second embodiment. In the flowchart shown in FIG. 6, a predetermined amount of the liquid resin material Mf is stored in a storage tank 300 provided in the resin molding apparatus 1000 in advance as preparation for manufacturing, and the pellet-shaped resin material Mp is stored in the material supply unit 610 of the injection unit 600. Supply. Then, the resin material Mp heated and plasticized by a heater (not shown) provided in the cylinder 620 is advanced to a state where it is conveyed to the injection port 620b. This manufacturing preparation is completed, and the flowchart shown in FIG. 6 is started.

  In the description of the resin molding method according to the second embodiment, a method of molding the second molded body 900 described in the first embodiment will be described by taking the form shown in the external perspective view of FIG. 7 as an example. Hereinafter, the second molded body 900 is referred to as a molded body 900. As illustrated in FIG. 7, the molded body 900 has a frustoconical outer shape having a cross-sectional shape 900 a, and illustrates a container including an internal space and a bottom.

(Molded product single layer forming process)
First, a molded product single layer forming step (S1) is performed. A detailed flowchart of the molded product single layer forming step (S1) is shown in FIG.

(The stage / table is driven to the molding start position)
The storage tank 300 in which the liquid resin material Mf is stored in the preparation step described above and the table 410 provided in the storage tank 300 are driven by the stage driving device provided in the base 100, and the table is driven to the molding start position ( Step S11) is executed. In the step of driving the table to the molding start position (S11), as shown in FIG. 9, the interval Duv between the forming surface 410a of the table 410 and the ultraviolet emitting unit 500a of the ultraviolet irradiating unit 500 is set to a predetermined interval. The relative position between the table 410 and the ultraviolet irradiation unit 500 is set. The predetermined interval of the interval Duv is a distance that can be reached by the energy with which the ultraviolet ray UV irradiated from the ultraviolet irradiation unit 500 can cure the liquid resin material Mf immediately above the formation surface 410a. Then, the table 410 and the storage tank 300 are moved such that the relative position between the table 410 and the storage tank 300 is a position where the formation surface 410a is at the depth D _L1 from the liquid surface Sf of the liquid resin material Mf. The depth D _L1 is the molding thickness of the first layer to be molded first, which will be described later.

(UV irradiation process)
When the ultraviolet irradiation unit 500 is disposed at a predetermined relative position with respect to the table 410, an ultraviolet irradiation step (S12) is executed. In the ultraviolet irradiation step (S12), the ultraviolet irradiation unit 500 moves relative to the table 410 while irradiating the ultraviolet ray UV from the ultraviolet irradiation unit 500 while maintaining the depth D _L1 as shown in FIG. The stage 200 is driven. The first layer mold forming in which the first layer molding region 801s is formed on the inner side by moving the ultraviolet irradiation unit 500 relative to the outer shape of the molded body 900 shown in FIG. A first mold layer 801 as a single object layer is formed. And it transfers to a single layer injection molding process.

(Single layer injection molding process)
In the single-layer injection molding step (S2), the first molding die layer 801 as the first molding single layer formed by the ultraviolet irradiation step (S12) on the forming surface 410a of the table 410 is used as a mold frame. A single layer as a part of the molded body 900 is injection molded. FIG. 11 shows a detailed flowchart of the single-layer injection molding step (S2).

(The table is driven to the injection molding start position)
In the single-layer injection molding step (S2), first, as shown in FIG. 12, the stage 200 is driven so that the injection port 620b of the injection unit 600 is disposed at the injection start position with the injection unit 600 as a relative position with respect to the table 410. The table is driven to the injection molding start position (S21). At this time, the stage 200 is driven without changing the depth D _L1 of the formation surface 410a of the table 410 from the liquid surface Sf of the liquid resin material Mf.

(Injection molding process)
When the step of driving the table to the injection molding start position (S21) is executed, the table is transported to the injection port 620b of the injection unit 600 in the preparation process, and exceeds the glass transition point of the resin material Mp by the heater provided in the injection unit 600. As shown in FIG. 13, the heated and plasticized resin material Mp is injected toward the table 410 from the injection port 620b with a predetermined pressure. At this time, the resin material Mp is injected and filled into a molding region 801 s which is a cavity formed inside the first molding die layer 801 formed in the mold molding single layer forming step (S 1).

  The injection state of the resin material Mp from the injection port 620b of the injection unit 600 shown in FIG. 13 will be described with reference to FIG. For convenience of explanation in FIG. 14, the plasticized resin material Mp is referred to as a plastic resin Mpf, and the resin material Mp solidified from the plasticized state is referred to as a solidified resin Mps.

  As shown in FIG. 14, the plastic resin Mpf is pressurized by the rotational drive of the flat screw 630 and is injected from the injection port 620b. The injected plastic resin Mpf is cooled to a temperature lower than the glass transition point in the process of reaching the formation surface 410a of the table 410, so that the form changes to the solidified resin Mps. The plastic resin Mpf is continuously laminated and solidified on the solidified resin Mps, and the solidified resin Mps is formed as a molded product in the molding region 801s of the first mold layer 801.

  At this time, since the uncured liquid resin material Mf remains inside the first mold layer 801 formed in a frame shape, the plastic resin Mpf touches the remaining liquid resin material Mf. It is possible to promote solidification by cooling to become the solidified resin Mps. Therefore, it is possible to shorten the time of the plastic resin Mpf state on the forming surface 410a, to prevent unnecessary flow in the XY direction shown in the figure, that is, so-called outflow, and to perform molding with an accurate shape. it can.

  As described above, the injection unit 600 provided in the resin molding apparatus 1000 according to the first embodiment used in the resin molding method according to the present embodiment is a method of injecting the plastic resin Mpf by applying pressure from the injection port 620b. This is one embodiment of a so-called injection molding method.

  Then, as shown in FIG. 15, while injecting the plasticized resin material Mp from the injection port 620b, the stage 200 is driven so that the injection unit 600 moves along a predetermined path relative to the table 410, and the first The resin material Mp is disposed in a molding region 801s constituted by the molding die layer 801, and a first molding layer 901 as a first molding single layer is formed. In the present embodiment, since the formation of the molded body 900 shown in FIG. 7 is illustrated, the first molded layer 901 corresponds to the bottom of the molded body 900 and is formed in a flat plate shape.

  When the first molding layer 901 of the first layer is formed, the injection molding process (S22) in the single-layer injection molding process (S2) is completed, and then the process proceeds to the stacking number confirmation process (S3).

(Stacking number confirmation process)
In the resin molding method according to the present embodiment, the first molded mold layer 801 and the single layer of the first molded layer 901 are stacked up to N layers (N: a natural number of 1 or more) to form the molded body 900. . Therefore, in the single-layer injection molding step (S2) immediately before the number-of-stacks confirmation step (S3), a number-of-stacks confirmation step (S3) for determining whether or not layers up to the N layers are performed.

  In the stacking number confirmation step (S3), when the number of stacked single layers of the molded product is smaller than N (NO) in the immediately preceding single layer injection molding step (S2), the process proceeds to the stacking step (S4).

(Lamination process)
The laminating step (S4) in the resin molding method according to the present embodiment is a command step for executing the repetitive molding single layer forming step (S1) and the single layer injection molding step (S2). Mold molding lamination step (S41) instructing repetition of the molding single layer formation step (S1) for newly forming a molding single layer on the uppermost mold molding single layer confirmed in the step (S3) ) And a molding laminate process (S2) for instructing repetition of a single-layer injection molding process (S2) for newly forming a molding monolayer on the uppermost molding monolayer confirmed in the lamination number confirmation process (S3) ( S42). In accordance with the command issued in the mold molding lamination step (S41) included in the lamination step (S4), a new mold molding single layer is molded on the uppermost mold molding single layer already formed on the table 410. The process proceeds to the molded product single layer forming step (S1).

In the mold product single layer forming step (S1) executed based on the command of the mold product stacking step (S41) included in the stacking step (S4), first, the step of driving the table to the molding start position (S11) is executed. Is done. As shown in FIG. 16, in the step of driving the table to the molding start position (S11), the upper surface of the first mold layer 801 as the first mold molded product single layer formed on the table 410, and the ultraviolet irradiation unit The relative positions of the table 410 and the ultraviolet irradiation unit 500 are set so that the 500 ultraviolet emitting units 500a have a distance Duv. The interval Duv in the step of driving the table relating to the stacking step (S4) to the molding start position (S11) is the ultraviolet ray irradiated from the ultraviolet irradiation unit 500 by the liquid resin material Mf directly above the first mold layer 801. The distance at which energy that can be cured is reachable. Then, the table 410 and the storage tank 300 are positioned relative to each other so that the upper surface of the first mold layer 801 is at a depth D _L2 from the liquid surface Sf of the liquid resin material Mf. Move. The depth D _L2 is the molding thickness of the second layer of the molded product single layer.

Next, the process proceeds to the ultraviolet irradiation step (S12). In the ultraviolet irradiation process (S12) according to the molded product lamination step (S41) included in the lamination step (S4), the ultraviolet ray UV irradiation unit 500 irradiates ultraviolet rays UV while maintaining the depth D _L2 as shown in FIG. The stage 200 is driven so that the ultraviolet irradiation unit 500 moves relative to the table 410 and follows the shape of the molded body 900. And the 2nd shaping | molding die layer 802 as a 2nd 2nd shaping | molding molding single layer is formed by the ultraviolet irradiation part 500 moving relatively, irradiating ultraviolet-ray UV. The second molding die layer 802 includes a second molding outer mold layer 802a for forming the outer shape of the molded body 900 and a second molding inner mold layer 802b for forming the inner side of the molded body 900. The The second molding outer mold layer 802a is laminated on the first first molding mold layer 801, but the molded body 900 exemplified in the present embodiment is formed by the first molding layer 901 serving as a flat bottom. Therefore, the second molded inner mold layer 802b is laminated on the first molded layer 901. And the 2nd molding area | region 802s enclosed by the 2nd shaping | molding outer mold layer 802a and the 2nd shaping | molding inner mold layer 802b is comprised.

  Subsequently, a single layer injection molding step (S2) related to the molded product laminating step (S42) included in the laminating step (S4) is performed, and the second layer is formed on the first molded layer 901 as the first molded single layer. The second molded product single layer is formed. As shown in FIG. 18, the single-layer injection molding step (S2) related to the stacking step (S4) is the second molding die layer 802 formed by the mold single layer forming step (S1) related to the stacking step (S4). The resin material Mp plasticized from the injection port 620b is injected into the molding region 802s while the injection port 620b of the injection unit 600 is moved relative to the table 410 so as to face the molding region 802s. And the 2nd molding layer 902 as a 2nd 2nd molding single layer which comprises the molded object 900 with the injected resin material Mp is formed.

  When the second molding layer 902 is formed by the single-layer injection molding step (S2) related to the molding lamination step (S42) included in the lamination step (S4), the process proceeds to the lamination number confirmation step (S3), and the number of laminations is confirmed. In the single-layer injection molding step (S2) immediately before the step (S3), it is determined whether up to N layers have been laminated. When the number of stacked single layers of the molded product is smaller than N (NO) in the immediately preceding single layer injection molding step (S2), the process proceeds to the stacking step (S4) again.

  In the above-described laminating step (S4), the first mold single layer, the second mold single layer, the first mold single layer, and the first single mold second layer, The second means simply the order, not the number of layers. For example, when the fourth mold layer 804 as the fourth layer is laminated on the third mold layer 803 as the third layer, the third mold layer 803 is referred to as a first mold product single layer, and the fourth mold is formed. The mold layer 804 is referred to as a second mold product single layer. Similarly, when the fourth molded layer 904 of the fourth layer is laminated on the third molded layer 903 of the third layer, the third molded layer 903 is called a first molded product single layer, and the fourth molded layer 904 is This is called the second molded product single layer.

  As shown in FIG. 19, the lamination step (S4) is repeated a predetermined number of times, and as shown in FIG. 19, as a molded body in which N layers from the first molding die layer 801 to the N-th molding die layer 80N are laminated. Using the first molded body 800 and the first molded body 800 as a molding die, a resin material Mp is injected into a so-called cavity in the molding regions 801s, 802s, 803s,. To a N-th molded layer 90N, a molded body 900 is formed as a second molded body in which N layers are stacked. Then, the process proceeds to the stacking number confirmation step (S3), and it is determined that the N layers have been stacked (YES), and the process proceeds to the mold release step.

(Release process)
The mold release step (S5) is a step of separating the molded body 900 from the first molded body 800 and taking out the molded body 900. As the release step (S5), release by physical means or release by chemical means is used. As a physical mold release means, the first molded body 800 is broken by applying an impact to the first molded body 800 with a hammer or the like, and high pressure air is pressed into the boundary between the first molded body 800 and the molded body 900. Means such as separating 800 and molded body 900 can be applied.

  As the chemical release means, it is preferable to apply a release means for separating the molded body 900 by immersing the ultraviolet curable resin constituting the first molded body 800 in a solvent that selectively dissolves. Thereby, there is no possibility of damaging the molded object 900, and it can mold-separate from the 1st molded object 800. FIG.

  The resin molding method according to the second embodiment by the resin molding apparatus 1000 according to the first embodiment is a known three-dimensional resin molding in which an injection molding die for obtaining a molded body 900 uses a resin that is cured by energy rays. It is formed as a resin mold by the method. As a result, it is possible to achieve a significant reduction in mold production time and a reduction in equipment costs by eliminating the need for a metal processing apparatus for mold production.

  In the resin molding method according to the present embodiment, the resin material Mp constituting the molded body 900 is not limited as long as it is a thermoplastic resin that can be injection-molded. That is, in the conventional method for forming a three-dimensional resin molding using a resin that is cured by energy rays, a monomer that can contain a catalyst that generates radicals by energy rays, such as an acrylate radical polymerization resin and an epoxy. It is limited to cationic polymerization resin. However, the resin molding method according to the present embodiment is not suitable for energy-curable curable resins. For example, as a crystalline resin, Pe (polyethylene), PP (polypropylene), PA (polyamide), POM (polyacetal), PBT ( Polybutylene terephthalate), PPS (polyphenylene sulfide), PEEK (polyether ether ketone) and the like. An example of the liquid crystalline resin is LCP (Liquid Crystal Polymer). As the amorphous resin, PS (polystyrene), ABS, PMMA (acrylic), PC (polycarbonate), PPE (polyphenylene ether), or the like can be applied.

  DESCRIPTION OF SYMBOLS 100 ... Base, 200 ... Stage, 300 ... Storage tank, 400 ... Molding part, 500 ... Energy ray irradiation part (ultraviolet irradiation part), 600 ... Injection | emission part, 700 ... Control unit, 1000 ... Resin molding apparatus.

Claims (9)

Stage,
A storage tank installed on the stage;
An energy ray irradiating unit for irradiating energy rays;
An injection part that plasticizes the first material, which is a synthetic resin, and injects it from an injection port;
The stage, and the energy beam irradiating unit and the emitting unit include a driving unit that enables relatively three-dimensional movement,
The storage tank has a table that can be driven at least in the direction of gravity inside, and stores a liquid second material containing an energy beam curable resin that is cured by the energy beam.
A resin molding apparatus characterized by that. The energy beam irradiated from the energy beam irradiation unit cures the second material to form a first molded product in a layer shape,
The first material injected from the injection portion is cured, and a second molded product is formed in a layer shape,
A first molded body in which the first molded product is laminated in the direction of gravity and a second molded body in which the second molded product is laminated in the direction of gravity are formed.
The resin molding apparatus according to claim 1. A cavity for forming the second molded body is formed in the first molded body, and the second molded body is injected and filled with the second material toward the cavity.
The resin molding apparatus according to claim 2.   The resin molding apparatus according to any one of claims 1 to 3, wherein the energy rays are ultraviolet rays.   The resin molding apparatus according to claim 1, wherein the synthetic resin is a thermoplastic resin. A liquid second material containing an energy ray curable resin stored in a storage tank installed on the stage is irradiated with energy rays, and the energy ray curable resin is cured to form a single layer molded product single layer. A mold product single layer forming step to be formed; and
Single-layer injection molding process in which the first material, which is a plasticized synthetic resin, is injected and filled from the injection part toward the molding region formed in the mold molded product single layer to form a molded product single layer When,
A mold molding lamination step of laminating the first mold molding monolayer formed by the mold molding monolayer formation step, and forming a second mold molding monolayer by the mold molding monolayer formation step; ,
A first product single layer formed by the single layer injection molding step, and a second product single layer formed by the single layer injection molding step.
The mold molding laminated step is repeated a predetermined number of times, and a mold molded body in which the mold molding single layer is laminated by a predetermined number of layers, and
Repeating the molding lamination step a predetermined number of times to form a molded body laminated in the molding region of the molded body,
The resin molding method characterized by the above-mentioned. Including a mold release step of releasing the molded body from the mold molded body,
The mold release step dissolves the molded body;
The resin molding method according to claim 6.   The resin molding method according to claim 6, wherein the energy rays are ultraviolet rays.   The resin molding method according to claim 6, wherein the synthetic resin is a thermoplastic resin.

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