JP2021187142A - Resin block manufacturing device, resin product manufacturing method and resin block manufacturing method - Google Patents

Abstract

To provide a device and a method of efficiently manufacturing a resin block and a resin product.SOLUTION: A resin block manufacturing device comprises: a material chamber to which a resin material is fed; a gate part which is arranged at an end surface of the material chamber and in which a plurality of holes are formed; heating means which heats the gate part; an extrusion part which presses the resin material fed to the material chamber to the heated gate part, to extrude the molten resin material from the holes; and a mold part which has a resin block molding space for housing the extruded resin material and, by gradually increasing the volume of the resin block molding space while applying pressure in a gate part direction to the extruded resin material, integrates the extruded resin material in the resin block molding space.SELECTED DRAWING: Figure 1

Description

The present invention relates to the production of a resin block, and more particularly to a resin block manufacturing apparatus, a resin product manufacturing method, and a resin block manufacturing method capable of efficiently manufacturing a resin block having a desired size (thickness).

Prototyping of resin products is usually done by carving out a resin block or using a 3-D printer, but in either case, the materials that can be used are limited, and the evaluation of the material that you want to use in mass production is appropriate. It may not be possible. Further, the method using a 3-D printer has a problem of dimensional accuracy and warpage, or a problem that the material is expensive and costly. Therefore, if it is desired to correctly evaluate the characteristics of the resin molded product when it is mass-produced and commercialized, it is necessary to manufacture a prototype by the same equipment and process as at the time of mass production. That is, for example, it is necessary to manufacture a mold similar to that at the time of mass production, use a resin material to be used, and actually operate an injection molding machine to perform injection molding to form a prototype. As a result, it is inevitable that the trial production will take time, cost, labor, and the like.

Therefore, the inventors of the present application have already disclosed an apparatus and a method capable of manufacturing a resin block using a resin material such as a desired material and color (see Patent Document 1), which is desired more efficiently. There is a desire to manufacture a resin block of the size (thickness) of. In addition, there is a demand for the trial production itself to be performed more efficiently, that is, at low cost and easily in a short period of time.

Japanese Unexamined Patent Publication No. 2019-151009

The present invention has been made in view of such a situation, and an object of the present invention is to be able to more efficiently manufacture a resin block using a resin having a desired material and color, that is, arbitrary. It is an object of the present invention to provide a resin block manufacturing apparatus and a resin block manufacturing method capable of more efficiently manufacturing a resin block of the resin material of the above. Further, an object of the present invention is a resin block manufacturing apparatus and a resin product manufacturing method capable of more efficiently performing a trial production itself, that is, capable of easily manufacturing a prototype of a resin product at low cost in a short period of time. Is to provide.

The resin block manufacturing apparatus of the present invention is
A material room that houses the resin material to be supplied, and
A gate portion in which a plurality of holes are formed and arranged on the end face of the material chamber,
A heating means for heating the gate portion and
An extrusion portion that presses the resin material supplied to the material chamber against the heated gate portion and extrudes the melted resin material from the holes.
The resin block molding space for accommodating the extruded resin material is provided, and the volume of the resin block molding space is gradually expanded while applying pressure toward the gate portion to the extruded resin material, and the extruded resin material is said to be extruded. It is characterized by having a mold portion for integrating the resin material in the resin block molding space.

Preferably, the resin block manufacturing apparatus of the present invention further comprises a pressure adjusting means for adjusting a pressure for pushing the resin material out of the hole and a pressure applied to the pushed out resin material toward the gate portion. And.

Further, preferably, the resin block manufacturing apparatus of the present invention is further characterized by further having a cooling means for cooling the gate portion and the mold portion.

Preferably, the mold portion defines a side surface of the resin block molding space, and has a side mold plate on which the gate portion is arranged on one end side, and a holding surface parallel to the gate portion. The space surrounded by the side template has a holding plate that can move in a direction perpendicular to the gate portion, the holding surface is parallel to the gate portion, and the space surrounded by the side template is described. It has a holding plate that can be moved in a direction perpendicular to the gate portion, and by moving the holding plate, the volume of the resin block molding space is gradually expanded while applying the pressure to the extruded resin material. It is characterized by doing.

Preferably, in the resin block manufacturing apparatus of the present invention, the mold portion moving means for moving the side template in the direction perpendicular to the gate portion and the side template are moved to a position away from the gate portion. In the state, the resin block formed inside the side template and the extruded block arranged between the gate portion are further provided, and the extruded block is arranged between the resin block and the gate portion. It is characterized in that the resin block is separated from the side mold plate by moving the side mold plate in a direction approaching the gate portion by the mold portion moving means in this state.

Further, preferably, each of the plurality of holes is characterized in that the opening diameter on the resin block molding space side is a truncated cone shape having a diameter larger than the opening diameter on the material chamber side.

Further, the resin block manufacturing apparatus of the present invention further has a prototype mold portion having a cavity corresponding to the shape of a desired resin molded product and a resin flow passage connecting the cavity and the resin block molding space. May be good.

Preferably, a prototype hole for communicating with the resin inflow passage is formed on the inner peripheral surface of the resin block molding space of the mold portion, and the resin block manufacturing apparatus of the present invention has the prototype hole. It is characterized by further having a prototype gate opening / closing pin for controlling the communication state between the cavity and the resin block molding space by opening / closing.

Further, in the resin product manufacturing method of the present invention, the resin material is desired by applying pressure to the melted resin material accommodated in the resin block molding space in the resin block manufacturing apparatus having the prototype mold portion. It is characterized in that a resin product corresponding to the shape of the cavity is manufactured by filling the cavity of the prototype portion having the cavity of the shape.

Preferably, the resin material is a resin pellet or a pulverized resin.

Further, the resin block manufacturing method of the present invention is as follows.
A step of extruding the melted resin material from the holes by pressing the resin material against the gate portion where a plurality of holes are formed and heated.
By gradually expanding the volume of the resin block molding space accommodating the extruded resin material while applying pressure toward the gate portion to the extruded resin material, the extruded resin material is subjected to the resin block. It is characterized by having a process of integrating in a molding space.

Preferably, in the resin block manufacturing method of the present invention, the pressure applied to the extruded resin material toward the gate portion is smaller than the pressure for extruding the melted resin material from the holes.

Preferably, the resin block manufacturing method of the present invention further comprises a step of cooling the resin material integrated in the resin block molding space, and the cooling applies pressure to the resin material toward the gate portion. It is characterized by doing it in addition.

Preferably, the resin material is a resin pellet or a pulverized resin.

According to the present invention, a resin block using a resin having a desired material and color can be manufactured more efficiently, that is, a resin block made of any resin material can be manufactured more efficiently. An apparatus and a method for manufacturing a resin block can be provided. Further, according to the present invention, the prototype itself can be performed more efficiently, that is, the resin block manufacturing apparatus and the resin product manufacturing method capable of easily manufacturing a prototype of a resin product at low cost in a short period of time. Can be provided.

FIG. 1 is a perspective view showing the overall configuration of the resin block manufacturing apparatus according to the first embodiment of the present invention. FIG. 2 is a cross-sectional view of the resin block manufacturing apparatus shown in FIG. 1 in II-II. FIG. 3 is a first cross-sectional perspective view showing the configuration and operation of the material chamber and the gate portion of the resin block manufacturing apparatus shown in FIG. 1. FIG. 4 is a second cross-sectional perspective view showing the configuration and operation of the material chamber and the gate portion of the resin block manufacturing apparatus shown in FIG. 1. 5A and 5B are views showing the configuration of a gate portion of the resin block manufacturing apparatus shown in FIG. 1, FIG. 5A is a perspective view, and FIG. 5B is a cross-sectional view at a portion V in FIG. 5A. FIG. 6 is a schematic diagram for explaining a process of molding a resin block in the resin block manufacturing apparatus shown in FIG. 1. FIG. 7 is a schematic diagram for explaining a cooling process in the resin block manufacturing apparatus shown in FIG. FIG. 8 is a first schematic diagram for explaining a mold release step in the resin block manufacturing apparatus shown in FIG. 1. FIG. 9 is a second schematic diagram for explaining a mold release step in the resin block manufacturing apparatus shown in FIG. 1. FIG. 10 is a perspective view showing the configuration of the resin block manufacturing apparatus according to the second embodiment of the present invention. FIG. 11 is a first cross-sectional perspective view showing the configuration and operation of the prototype portion of the resin block manufacturing apparatus shown in FIG. 10. FIG. 12 is a second cross-sectional perspective view showing the configuration and operation of the prototype portion of the resin block manufacturing apparatus shown in FIG. 10.

First Embodiment The first embodiment of the present invention will be described with reference to FIGS. 1 to 9.
In the present embodiment, the present invention will be described by illustrating a resin block manufacturing apparatus 1 that manufactures a resin block from resin pellets (sometimes referred to simply as pellets). The resin block manufacturing apparatus 1 of the present embodiment is an apparatus capable of manufacturing a resin block having a desired thickness by heating and melting the pellets and then cooling and curing the pellets.

As shown in FIGS. 1 and 2, the resin block manufacturing apparatus 1 includes a material chamber 100, a gate section 200, a heater (heating means) 250, a cooling section (cooling means) 270, an extrusion section 300, a mold section 500, and a control. It has a part 630. The resin block manufacturing apparatus 1 has, for example, a frame formed by connecting angle members, and is equipped with various mechanisms and units described later.

First, the configuration and function of each part of the resin block manufacturing apparatus 1 will be described.

The material chamber 100 accommodates the resin material to be supplied. As shown in FIGS. 1 and 2, the material chamber 100 has a configuration (referred to as a rectangular tubular portion) 110 in which rectangular tubular members are arranged with the horizontal direction (X-axis report) as the cylindrical axial direction. A gate portion 200, which will be described later, is installed at one end of the rectangular tubular portion 110. Further, inside the rectangular tubular portion 110, a material extrusion plate 320 of the extrusion portion 300, which will be described later, is disposed so as to be movable in the cylindrical axial direction. The space surrounded by the inner peripheral surface 112 of the rectangular tubular portion 110, the gate portion 200, and the material extrusion plate 320 of the extrusion portion 300 is the material storage space 102 for accommodating the pellets as raw materials. A material input port 120 for supplying pellets to the material storage space 102 is formed on the upper surface of the material storage space 102.

The material chamber 100 may be made of any metal material, but in the present embodiment, it is made of an aluminum plate material.

The gate portion 200 is a member for melting the pellets supplied to the material storage space 102 of the material chamber 100 and allowing the melted resin material to flow out to the resin block molding space 502 of the mold portion 500.
The gate portion 200 is installed between the material chamber 100 and the mold portion 500, the material chamber side surface 201 forms one end surface of the material storage space 102, and the mold portion side surface 203 is a resin block molding space. Form one end face of 502.

As shown in FIG. 5A, the gate portion 200 is formed with a large number of holes 210 penetrating between the material chamber side surface 201 and the mold portion side surface 203. The holes 210 are holes for allowing the molten resin material to flow out from the material accommodating space 102 to the resin block molding space 502. As shown in FIG. 5B, the inner peripheral surface of each hole 210 is inclined at a predetermined angle α from the material chamber side opening (resin inlet) 221 toward the resin block molding space side opening (resin outlet) 222. It is a truncated cone-shaped hole that expands in diameter. That is, each hole 210 has a truncated cone shape in which the opening diameter of the resin block molding space side opening 222 is larger than the opening diameter of the material chamber side opening 221. By forming the holes 210 in a truncated cone shape having such a tapered peripheral surface, it becomes easy to release the resin block molded in the resin block molding space 502.

In the present embodiment, the inner peripheral surface of the hole 210 is inclined and expanded from the material chamber side opening (resin inlet) 221 toward the resin block molding space side opening (resin outlet) 222. It is a truncated cone-shaped hole. The size of the material chamber side opening (resin inflow port) 221 is a size that the pellet used as a raw material does not enter the hole 210, that is, a size smaller than the diameter of the pellet used (maximum value), and the molten resin material is Any size may be used as long as it can flow in (minimum value). However, if the diameter of the hole 210 is large (thick), it becomes difficult to release the molded resin block. Therefore, it is preferable that the hole 210 has a small diameter. Specifically, for example, the diameter φ of the resin inlet 221 is φ. Is 1.0 mm to 5.0 mm, preferably 0.5 mm to 3.0 mm. The inclination angle α of the inner peripheral tapered surface of the hole 210 is, for example, an angle larger than 0 ° and 15 ° or less, preferably 1 ° to 5 °.

Further, the number of holes 210 and the arrangement of the holes 210 may be any number and any arrangement as long as the holes 210 do not interfere with each other and can be formed independently. The larger the number of holes 210, the larger the amount of resin material flowing from the material storage space 102 to the resin block molding space 502, and the faster the resin block can be molded. On the other hand, the larger the number of holes 210, the larger the molded resin. It becomes difficult to remove the block. Further, the arrangement of the holes 210 is preferably uniform over the entire gate portion 200. Specifically, for example, it is preferable that the holes 210 are formed in a grid pattern or a zigzag pattern at a pitch of 5 mm to 15 mm in each of the vertical and horizontal directions (Y direction and Z direction).

The gate portion 200 may be made of any metal material, but in the present embodiment, it is made of aluminum.

As shown in FIG. 6, a temperature sensor 230 for detecting the temperature of the gate portion 200 is installed in the vicinity of the hole 210 of the gate portion 200. In this embodiment, the temperature sensor 230 is a thermocouple. The temperature sensor 230 is directly or indirectly connected to the control unit 630, and the control unit 630 can detect the temperature in the vicinity of the hole 210 of the gate unit 200.

The heater (heating means) 250 heats the gate portion 200 in order to melt the pellets accommodated in the material accommodating space 102 of the material chamber 100. The heater 250 is embedded in the gate portion 200. The heater 250 includes a range in which a large number of holes 210 of the gate portion 200 are formed, and heats the entire range in which one end face of the gate portion 200 material accommodating space 102 is formed substantially uniformly. The heater 250 is controlled by the control unit 630 to heat the gate unit 200 to a predetermined temperature according to the type of pellet used as a raw material. Specifically, the heater 250 has a gate portion 200 up to about the melting temperature of the resin material (pellet) used as a raw material, or empirically up to a temperature 30 ° to 40 ° higher than the temperature at which the resin material becomes soft and begins to melt. Is heated to raise the temperature.

The pellets accommodated in the material accommodating space 102 of the material chamber 100 are pressed against the material chamber side surface 201 of the gate portion 200 by the operation of the extrusion portion 300 described later. As described above, when the gate portion 200 is heated and raised by the heater 250, the pressed pellets are melted and flow into the resin block molding space 502 through each of the holes 210.

When the molding of the resin block is completed, the cooling unit 270 cools the gate unit 200 and the mold unit 500 described later. As shown in FIG. 7, the cooling unit 270 includes a gate unit 200 and a resin block forming space due to a cooling plate 271 cooled by a cooling device (not shown) and a cooling airflow 273 generated by a cooling airflow blower (not shown). The molded resin block RB present in 502 is cooled.

The cooling plate 271 is formed adjacent to the gate portion 200 or integrally with the gate portion 200, and is cooled by a cooling device (not shown) to cool the gate portion 200. As the cooling device for cooling the cooling plate 271, an oil-cooled type that cools the cooling plate 271 by using oil as a cooling medium, an air-cooled type that uses a gas such as air (wind) as a cooling medium, or water is used as a cooling medium. Any cooling type device such as a water-cooled type may be used.

The cooling airflow 273 is compressed air for cooling that is blown from below onto the mold plate 510 of the mold portion 500 by a cooling airflow blower (not shown). By cooling the template 510 by the cooling airflow 273, the molded resin block existing in the resin block molding space 502 inside the template 510 is cooled and cured. The cooling airflow 273 may be blown onto the template 510 not only from below the template 510 but also from above. Further, the template 510 may be further sprayed from the side of the template 510.

The extrusion section 300 presses the pellets supplied and stored in the material storage space 102 of the material chamber 100 against the heated gate section 200 to melt them, and the melted resin material is passed through the holes 210 of the gate section 200. , Is sent to the resin block molding space 502 of the mold portion 500. The extrusion unit 300 includes a material extrusion plate 320, an extrusion plate moving unit 324, an extrusion plate drive unit 326, and an extrusion plate control unit (not shown).

The material extrusion plate 320 is disposed inside the rectangular tubular portion 110 of the material chamber 100 so as to be inscribed in the inner peripheral surface 110 having a rectangular tubular configuration and to be movable in the cylindrical axial direction. The material extrusion plate 320 forms the other end face of the material storage space 102 facing the gate portion 200 inside the rectangular tubular portion 110 of the material chamber 100. The material extrusion plate 320 is connected to the extrusion plate drive unit 326 by an extrusion plate moving unit 324. In the present embodiment, the extrusion plate drive unit 326 is an actuator mechanism using a ball screw using a servo, but may be another drive device. The extrusion plate drive unit 326 is driven by an extrusion plate control unit (not shown) provided in the control unit 630. That is, the material extrusion plate 320 is moved by an extrusion plate control unit (not shown) provided in the control unit 630.

The mold portion 500 has a resin block molding space 502 for accommodating the resin material extruded from each hole 210 of the gate portion 200, and the resin block molding space 502 is gradually applied while applying pressure in the gate portion 200 direction to the extruded resin material. The volume of the resin is expanded and the extruded resin material is integrated in the resin block molding space 502.

The mold portion 500 has a configuration in which the rectangular tubular member is arranged with the horizontal direction (X-axis report) as the tubular axis direction, and has a side template 510 that defines the side surface of the resin block molding space 502. The gate portion 200 described above is installed at one end of the side template 510. The side stencil 510 is fixedly installed on the stencil 540 via a side stencil support rod 514 connected to the other end. The side template 510 may be made of any metal material, but in this embodiment, it is made of aluminum.

The mold portion 500 has a holding plate 520 that can move in a direction perpendicular to the gate portion 200 in a space surrounded by the side template portion 510. Further, the pressing plate 520 has a pressing surface 521 facing parallel to the gate portion 200. The space surrounded by the inner peripheral surface of the side template 510, the gate portion 200, and the holding plate 520 is the resin block molding space 502. The presser plate 520 is connected to the presser plate drive unit 526 by the presser plate drive rod 524. The holding plate 520 may be made of any metal material, but in the present embodiment, it is made of aluminum.

In the present embodiment, the holding plate driving unit 526 is an actuator mechanism using a ball screw using a servo, but may be another driving device. The presser plate drive unit 526 is driven by a presser plate control unit (not shown) provided in the control unit 630. That is, the holding plate 520 is moved by the holding plate control unit (not shown) provided in the control unit 630.

The pressing plate 520 is gradually moved away from the gate portion 200 according to the resin material extruded in the gate portion 200 from the state of being in contact with the mold portion side surface 203 of the gate portion 200. As a result, the pressing plate 520 functions to gradually increase the volume of the resin block molding space while applying pressure to the resin material extruded from the gate portion 200 into the resin block molding space 502.

Further, the mold tension plate 540 in which the side template 510 is installed via the side template support rod 514 is connected to the mold tension plate drive unit 546 by the mold tension plate drive rod 544, and is connected to the mold tension plate drive unit 546 in the horizontal direction (X-axis). It can be moved in a direction (direction perpendicular to the gate portion 200). As the mold tension plate 540 moves away from the gate portion 200, the side mold plate 510 moves integrally with the resin block formed in the resin block molding space 502 in the direction away from the gate portion 200. As a result, there is a space between the side template 510 and the gate portion 200 where the mold release extrusion block 580 can be placed.

As shown in FIG. 9, the mold release extrusion block 580 is a member in which two plate members 581 and 582 arranged to face each other are connected by a rod 583. The extrusion block 580 for mold release is configured to be movable in the vertical direction by the extrusion block moving portion 584. For example, when the side template 510 is in contact with the gate portion 200 as shown in FIG. 7, the extruded block 510 is configured to be movable in the vertical direction. It is retracted to the upper part of the side template 510. Further, as shown in FIG. 8, in order to release the molded resin block, the mold tension plate 540 moves in a direction away from the gate portion 200, and a space is created between the side mold plate 510 and the gate portion 200. When secured, the mold release extrusion block 580 is moved downward and placed between the side template 510 and the gate 200.

The mold release extrusion block 580 has a shape and size that allows it to enter the resin block molding space 502 inside the side template 510. The release block 580 does not need to be inscribed in the inner peripheral surface of the side template 510. When the mold tension plate 540 moves and the side mold 510 moves toward the gate portion 200, the plate material 581 on the side far from the gate portion 200 has a certain area and the side mold 510 has a certain area to a certain depth. Any form can be used as long as it can enter inside.

In such a configuration, after the resin block RB is formed in the resin block molding space 502, the mold release extrusion block 580 is arranged between the side mold plate 510 and the gate portion 200, and the mold tension plate 540 is gated. When the side template 510 is moved in the direction of the portion 200, the side template 510 can be moved in the direction of the gate portion 200 around the extruded block 580 for mold release, but the resin block RB formed inside the side template 510 is separated. It abuts on the die extrusion block 580 and stops moving in the direction of the gate portion 200. As a result, even if the resin block RB is attached to the inner peripheral surface of the side template 510, the resin block is released from the side template 510.

At this time, the holding plate 520 should be brought into contact with the end surface of the resin block RB on the opposite side of the gate portion 200 so that the resin block is sandwiched between the holding plate 520 and the mold release extrusion block 580. For example, even when the resin block is released and completely separated from the side mold 510, the resin block can be appropriately held.

The control unit 630 controls the operation of each unit of the resin block manufacturing apparatus 1. Specifically, the control unit 630 drives the heater 250 to raise the temperature of the gate unit 200 while detecting the temperature of the gate unit 200 via the temperature sensor 230, and drives the cooling unit 270 to drive the gate unit. The 200 is cooled and the gate portion 200 is controlled to a desired temperature state. Further, the control unit 630 controls the holding plate driving unit 526, the mold tension plate driving unit 546, and the extrusion block moving unit 584 so that the formed resin block is appropriately released and taken out.

Further, in the control unit 630, the force of pressing the pellet in the material accommodating space 102 by the material extrusion plate 320 against the gate unit 200 is slightly larger than the force of pressing the resin material flowing into the resin block molding space 502 by the pressing plate 520. The extrusion plate drive unit 326 and the presser plate drive unit 526 are controlled so as to be larger, and the pressures thereof are adjusted. With such a relative pressure relationship, a high-quality resin block without bubbles can be manufactured by the action described later.

Next, a method of manufacturing a resin block using the resin block manufacturing apparatus 1 having such a configuration will be described.
First, as an initial state, as shown in FIG. 3, the material extrusion plate 320 is retracted in a direction away from the gate portion 200 from the material input port 120 to secure a material storage space 102 capable of inputting materials and having a sufficient volume. At the same time, the holding plate 520 is kept in close contact with the gate portion 200, that is, the volume of the resin block molding space 502 is set to zero.
In this state, the pellets as the raw material are charged into the material storage space 102 of the material chamber 100 from the material input port 120. (Material input process)

Next, the heater 250 is controlled to raise the gate portion 200 to a predetermined temperature according to the type of pellet, that is, a temperature at which the pellet is in a molten state. (Heating process)

Next, the extrusion plate drive unit 326 is driven, the material extrusion plate 320 is moved in the direction of the gate portion 200 at a predetermined pressure, in other words, at a predetermined speed, and the pellets in the material chamber 100 are moved in the direction of the gate portion 200. Moves to, accumulates, and adheres to the gate portion 200. Further, the pressing plate driving portion 526 is driven, and the pressing plate 520 is pressed in the direction of the gate portion 200 with a predetermined pressure.
As a result, the pellets are arranged on the entire surface 201 on the material chamber side of the gate portion 200, and the pellets in the vicinity of the gate portion 200 are melted and extruded from the holes 210 into the resin block molding space 502 of the mold portion 500. (Extrusion process)

In the extrusion process, the material extrusion plate 320 and the pressing plate 520 are adjusted so as to exert an appropriate pressure for forming the resin block by pressure control by servo control. By making the pressing force of the pressing plate 520 slightly smaller than the pressing force of the material extrusion plate 320, the molten resin material enters between the pressing plate 520 and the gate portion 200, and the shape of the resin block forming space 502. A resin block is molded in. Further, the pressing plate 520 is in a pushed-down state with the molding of the resin block, the pressing plate 520 gradually moves in the direction away from the gate portion 200, and the volume of the resin block molding space is gradually expanded. Gradually grows.

Here, the process of removing bubbles in the extrusion process will be described with reference to FIG.
When the pellets in the material chamber 100 are moved and accumulated in the direction of the gate portion 200 by the material extrusion plate 320 and brought into close contact with the gate portion 200, the pellets take the form of pellets as they approach the gate portion 200 from the material extrusion plate 320. It becomes a maintained state (pellet state), a semi-melted state, and a melted state. At this time, in the pellet state, air bubbles are contained between the pellets, but in the semi-melted state, the air bubbles are removed and the pellet becomes in a molten state. Then, in the molten state, due to the application of pressure, the bubbles escape to the semi-melted state and the pellet state side where the density is low, the flow path of the bubbles remains, or the fluidity of the bubbles is high. Will be done. Due to such an action, only the resin material in which no air bubbles are present flows into the resin block molding space 502 of the mold portion 500. As a result, a resin block without bubbles is molded in the resin block molding space 502.

When the resin block grows to a desired thickness, the resin material integrated as the resin block is cooled in the resin block molding space 502. (Cooling process)
As shown in FIG. 7, the cooling is performed by cooling the gate portion 200 via the cooling plate 271 and blowing a cooling airflow 273 onto the side surface template 510 around the resin block molding space 502. At this time, a strong pressure (back pressure FB) is applied to the resin block RB in the gate portion 200 direction by the pressing plate 520.

By applying such a back pressure FB, it is possible to prevent so-called sink marks from occurring in the resin block RB due to shrinkage during cooling, and it is possible to prevent resin from being drawn in the vicinity of the gate portion 200.
Further, by using such a cooling method, the gate portion 200 is first cooled, and as soon as the cooling is started, the resin near the gate portion 200 is cured, so that the resin is not drawn from the gate portion 200 and the gate is gated. The hole 210 of the portion 200 is covered. As a result, the back pressure FB can be sufficiently applied to the resin block, and sink marks and the drawing of the resin can be appropriately prevented.

When the cooling is completed, the molded resin block RB is released from the side mold 510 and taken out. Since the molded resin block RB is attached to the side template 510, it is peeled off. (Release process)
In the mold release step, first, as shown in FIG. 8, by retracting the mold tension plate 540 (see FIG. 2) in the direction away from the gate portion 200, the side mold plate 510 and the molded resin block RB are separated. It is moved in a direction away from the gate portion 200. At this time, the holding plate 520 also moves together with the resin block RB while maintaining the state of being in contact with the end face of the resin block RB.
Next, the mold release extrusion block 580 is lowered and arranged between the side template 510 and the gate portion 200 generated by this. The surface of the release block 580 on the gate portion 200 side is arranged so as to be in close contact with the gate portion 200.

Next, the mold tension plate 540 is moved in the direction of the gate portion 200, and the side mold plate 510 and the resin block RB are moved in the direction of the gate portion 200. The side mold 510 and the resin block RB move integrally until the resin block RB comes into contact with the mold release extrusion block 580, but when the resin block RB comes into contact with the mold release extrusion block 580, the resin block RB Since the movement is blocked, only the side template 510 moves in the direction of the gate portion 200. As a result, the resin block RB is peeled off from the side template 510. Further, by moving the side template 510 toward the gate portion 200, the resin block RB is completely separated from the side template 510, and the release of the resin block RB is completed.

Until the resin block RB comes into contact with the mold release extrusion block 580, the holding plate 520 is also moved together with the resin block RB while maintaining the state of being in contact with the end face of the resin block RB. When the resin block RB comes into contact with the mold release extrusion block 580, the holding plate 520 stops at this position and maintains the state in which the resin block RB is sandwiched between the resin block RB and the mold release extrusion block 580. As a result, when the mold release of the resin block is completed, the resin block is held between the holding plate 520 and the mold release extrusion block 580, and the resin block manufacturing apparatus is held through a take-out means (not shown). Taken from 1.
In the resin block manufacturing apparatus 1 of the present embodiment, a resin block having a desired size is manufactured in this way.

As described above, in the resin block manufacturing apparatus of the present embodiment, resin pellets sold in various types and colors are melted and resin layers are sequentially laminated to form a resin block without using a molding machine. Therefore, it is possible to manufacture a resin block using a resin having a desired material and color, in other words, a resin block made of any resin material. Further, a resin block having a desired size can be manufactured within the length of the side template 510 (resin block molding space 502). As a result, it is possible to manufacture a resin block of a desired size of a desired resin material necessary for manufacturing a prototype by carving, and it is possible to appropriately evaluate the characteristics for mass production and commercialization in trial production and the like. It can be carried out.

Further, in the resin block manufacturing apparatus 1 of the present embodiment, a large number of holes 210 are formed to heat the gate portion 200, and the pellets are pressed against the holes to melt the gate portion 200, and the resin block molding space 502 is formed through the holes 210. It is leaked to. Therefore, it is difficult for air bubbles to enter the completed resin block, and an extremely high quality resin block can be manufactured.

Further, in the resin block manufacturing apparatus 1 of the present embodiment, the resin block RB is cooled while being pressurized, and the gate portion 200 is cooled so as to be cooled first, so that so-called sink marks and resin can be drawn in. It can be prevented and a high quality resin block with high dimensional accuracy can be manufactured.

Second Embodiment The second embodiment of the present invention will be described with reference to FIGS. 10 to 12 in addition to FIGS. 1 to 9.
The resin block manufacturing apparatus 2 of the second embodiment can perform a trial production of a resin product in addition to the function of the resin block manufacturing apparatus 1 of the first embodiment of manufacturing a resin block from resin pellets, that is, a resin. It is a device that has the function of molding a prototype of a product. In the following description, the same configurations, functions, operations, processes and methods as those of the resin block manufacturing apparatus 1 of the first embodiment are designated by the same reference numerals as those of the first embodiment in the drawings, and the description thereof will be omitted. ..

As shown in FIGS. 1, 2 and 10, the resin block manufacturing apparatus 2 of the second embodiment has a material chamber 100, a gate portion 200, a heater (heating means) 250, a cooling section (cooling means) 270, and an extrusion section. It has 300, a prototype mold unit 400, a mold unit 501, and a control unit 640. Of these, the configurations, functions, and operations of the material chamber 100, the gate unit 200, the heater 250, the cooling unit 270, and the extrusion unit 300 are the same as the functions of the corresponding parts of the resin block manufacturing apparatus 1 of the first embodiment. .. Further, the steps and methods for manufacturing the resin block in the resin block manufacturing apparatus 2 are also the same as the steps and methods in the resin block manufacturing apparatus 1 of the first embodiment.

The resin block manufacturing apparatus 2 of the second embodiment has a prototype unit 400 as a new configuration. Further, the mold unit 501 and the control unit 640 of the resin block manufacturing apparatus 2 of the second embodiment have the same configurations and functions as the mold unit 500 and the control unit 630 of the resin block manufacturing apparatus 1 of the first embodiment, and have the same configuration and function. Further, the resin block manufacturing apparatus 2 has a new configuration and function corresponding to having the prototype mold portion 400. Hereinafter, the configuration, functions, and the like of the prototype mold unit 400 and the mold unit 501 and the control unit 640 newly provided corresponding to the prototype mold unit 400 will be described.

As shown in FIG. 10, in the resin block manufacturing apparatus 2, the prototype mold portion 400 is installed on one side surface of the mold plate 511 of the mold portion 501. The prototype mold portion 400 is installed on the outside of one of the side plates parallel to the vertical direction (Z-axis direction) of the template 511. The prototype portion 400 is different from the resin block described in the first embodiment, and has a configuration for producing a resin molded product having a desired shape. As shown in FIG. 11, the prototype mold portion 400 has a cavity 420 having a desired shape inside, and the molten resin material flows from the resin block molding space 502 to form a shape corresponding to the shape of the cavity 420. Molded products are manufactured.

The prototype unit 400 has a prototype base 411, a prototype first unit 413, and a prototype second unit 415. The prototype base portion 411 is a member in which the prototype mold portion 400 is installed on the side surface of the template 511 and the prototype mold (including the prototype mold first portion 413 and the prototype mold second portion 415) is installed. The prototype base 411 is installed on the template 511 with screws (not shown). The method of installing the prototype base 411 on the template 511 may be a method other than screws, for example, a method such as bolts / nuts, rivets, and welding.

The prototype type 1 part 413 and the prototype type part 2 415 are members in which a cavity corresponding to the shape of the resin molded product to be manufactured is formed inside. The prototype first part 413 is installed with respect to the prototype base 411 by, for example, a screw (not shown). Further, the prototype second part 415 is also installed on the prototype first part 413 or on the prototype base 411 by, for example, a screw (not shown).

The prototype unit 400 has a resin flow passage 425 for pouring the molten resin material into the cavity 420. One end of the resin flow passage 425 communicates with a prototype horizontal hole 516 formed at the end of the template 511 on the gate portion 200 side, and the other end of the resin flow passage 425 is a prototype mold portion. It communicates with the cavity 420 of 400. When the molten resin material flows from the gate portion 200 to the mold portion 501 side and a resin block molding space 502 is formed between the holding plate 520 of the mold portion 501 and the gate portion 200, the trial horizontal hole 516 is a resin block. It will be open to the molding space 502. As a result, the molten resin material in the resin block molding space 502 is sent into the cavity 420 through the prototype horizontal hole 516 and the resin flow passage 425, and the cavity 420 is filled with the resin material.

As shown in FIGS. 11 and 12, one end of the resin flow passage 425, which is connected to the prototype horizontal hole 516, is formed substantially perpendicular to the side surface of the template 511 (Z-axis direction). It is formed as a part of the sliding hole 435 of the prototype gate opening / closing pin 430. The prototype gate opening / closing pin 430 moves in the Z-axis direction along the sliding hole 435, and the tip portion fits into the prototype horizontal hole 516 to close the prototype horizontal hole 516, or the prototype horizontal hole. It is arranged in an open position to open 516.

When the prototype gate opening / closing pin 430 is in the closed position, the prototype side hole 516 is closed, and the resin material in the resin block molding space 502 does not flow into the resin flow passage 425. In this state, the tip surface of the prototype gate opening / closing pin 430 is formed in the same plane as the inner peripheral surface of the template 511 in the space forming the resin block molding space 502, that is, in a so-called stencil state. It is configured. The resin block manufacturing apparatus 2 in this state is operated in the same manner as the resin block manufacturing apparatus 1 of the first embodiment, so that the resin block can be manufactured in the same manner as the resin block manufacturing apparatus 1.

When the prototype gate opening / closing pin 430 is in the open position, the prototype side hole 516 is opened and the resin flow passage 425 from the resin block molding space 502 to the cavity 420 is communicated. In this state, the molten resin material is sent from the gate portion 200 to the resin block molding space 502, and pressure acts on the molten resin material in the resin block molding space 502 by the pressing plate 520, whereby the inside of the resin block molding space 502. The resin material of the above is fed into the cavity 420 through the side hole 516 for trial production and the resin inflow passage 425. As a result, the cavity 420 is filled with the resin material, and a resin molded product corresponding to the shape of the cavity 420 is molded.

In the present embodiment, the cross-sectional shapes of the resin flow passage 425 and the trial horizontal hole 516 are the same rectangular cross-sectional shape in the entire area of the resin flow passage 425 and the trial horizontal hole 516, and the width thereof is, for example, several mm to several. It is cm (1.0 mm to 10.0 mm), and its height is, for example, several mm to several cm (1.0 mm to 10.0 mm).

The cross-sectional shapes of the resin inflow passage 425 and the side hole 516 for trial production are the size of the cavity 420 (the size of the resin molded product to be manufactured), the characteristics of the resin material used (viscosity, etc.), and the control of the resin block manufacturing apparatus 2. It may have any shape depending on the conditions (pressing pressure of the material extrusion plate 320 of the extrusion portion 300, heating conditions of the gate portion 200 by the heater 250, pressing pressure of the pressing plate 520 of the mold portion 501, etc.), for example, a cross section. It may be a circular hole.

Further, the cross-sectional shape of the resin flow passage 425 and the prototype horizontal hole 516 may be a passage having a sufficient height in the height direction. For example, when the width of the cross section of the resin flow passage 425 and the prototype horizontal hole 516 is 1.0 mm to 10.0 mm, the height may be about 10.0 mm to 200.0 mm. Alternatively, the height may be specified and designed as 10%, 30%, 50% or 100% of the height of the resin block molding space 502.

Further, the shape and size of the holes (passages, holes) may differ depending on the location (position).

Further, the shape of the prototype gate opening / closing pin 430 is arbitrary as long as the tip portion can close the prototype horizontal hole 516 and the whole can move between the closed position and the open position in the sliding hole 435. The shape may be used.

In the resin block manufacturing apparatus 2 having such a configuration, both the resin block and the prototype of the resin product can be manufactured.

When manufacturing the resin block, as described above, the prototype gate opening / closing pin 430 may be arranged at the closed position, and the resin block manufacturing apparatus 2 may be operated in the same manner as the resin block manufacturing apparatus 1 of the first embodiment. .. At this time, since the prototype mold portion 400 is installed with respect to the mold plate 511 of the mold portion 501, it moves together with the mold plate 511, but it has no effect on the production of the resin block, and the first embodiment has no effect. Similar to the resin block manufacturing apparatus 1, a resin block having a desired size can be manufactured.

Even when a prototype of a resin product is manufactured using the resin block manufacturing apparatus 2, the prototype gate opening / closing pin 430 is arranged at a closed position in the initial state. Then, the same process as in the case of manufacturing the resin block is carried out. That is, the holding plate 520 of the mold portion 501 is brought into close contact with the gate portion 200, the pellets as the raw material are put into the material storage space 102 of the material chamber 100, and the temperature at which the pellets are melted in the gate portion 200 by the heater 250. By moving and pressing the material extrusion plate 320 toward the gate portion 200 with a predetermined pressure, the molten resin material is extruded from the hole 210 of the gate portion 200 into the resin block molding space 502 of the mold portion 501.

In this state, by setting the pressing force of the pressing plate 520 of the mold portion 501 to be slightly smaller than the pressing force of the material extrusion plate 320, the molten resin material enters between the pressing plate 520 and the gate portion 200. , The resin block is molded into the shape of the resin block molding space 502. Then, the pressing plate 520 is pushed away with the molding of the resin block, the pressing plate 520 gradually moves in the direction away from the gate portion 200, and the volume of the resin block forming space 502 is gradually expanded.

When manufacturing a prototype of a resin product, the subsequent steps are different from those when manufacturing a resin block.
When the resin material having a predetermined thickness is fed into the resin block molding space 502, the trial gate opening / closing pin 430 is opened, and the pressing force of the pressing plate 520 of the mold portion 501 is increased to pass through the gate portion 200. The pressing plate 520 is in a state of not being defeated by the supply of the resin material or the pressurization by the material extrusion plate 320 of the extrusion unit 300. As a result, the resin material in the resin block molding space 502 is sent to the cavity 420 of the prototype mold portion 400 through the prototype horizontal hole 516 and the resin flow passage 425, the cavity 420 is filled with the resin material, and the shape of the cavity 420 is formed. A resin molded product corresponding to the above is molded.

When the cavity 420 of the prototype mold 400 is filled with the resin material, the prototype mold portion 400 is cooled together with the gate portion 200 and the mold portion 501, and when the cooling is completed, the prototype mold portion 2 415 and the prototype mold portion 415 of the prototype mold 410 are cooled. By separating (opening the mold) from the first part 413, the molded prototype is released and taken out. Thereby, a desired resin molded product can be obtained.

As described above, by using the resin block manufacturing apparatus 2 of the second embodiment, it is possible to efficiently manufacture a prototype of a resin product. Since the resin block manufacturing apparatus 2 includes a pressure control means for manufacturing the resin block, the prototype of the resin product can be manufactured by the trial mold unit 400 using the pressure control means, so that the product can be manufactured at low cost, easily and with high accuracy. It is possible to manufacture a prototype of a resin product having a desired shape.

Further, the mold used in the resin block manufacturing apparatus 2 may be manufactured as long as the cavity 420 and the resin flow passage 425 are formed, and can be manufactured easily and inexpensively as compared with the mold used in a normal injection molding machine. Therefore, the prototype can be manufactured easily, at low cost, in a short period of time, that is, extremely efficiently, as compared with the case where the prototype is manufactured by the same method as in mass production using an injection molding machine.

In the present embodiment, one prototype mold part 400 is installed on one side surface of the mold part 511 of the mold part 500, and a configuration and a method for manufacturing a prototype of one resin product have been described. However, if the new prototype unit 400 is installed on the opposite side surface, two prototypes can be manufactured at the same time, and the resin block manufacturing apparatus 2 may be implemented in such a form.

Further, the place where the prototype mold portion 400 is installed is not limited to the side surface of the template 511 (the surface facing the Y-axis direction), and may be installed on the side surfaces facing vertically. Further, the number of prototype units 400 to be installed on one side surface is not limited to one, and two or more may be installed. An arbitrary number of prototype mold portions 400 may be installed on the template 511 depending on the size of the prototype to be manufactured (size of the prototype mold portion 400) and the like.

Further, the method of driving the prototype gate opening / closing pin 430, the method of controlling each part of the resin block manufacturing apparatus 2 in the control unit 640, and the like may be any method.

Modifications The present invention is not limited to the above-mentioned first embodiment and the second embodiment, and various suitable modifications can be made.
For example, the resin block manufacturing apparatus of the present invention is a horizontal type apparatus in which the main operating direction is the horizontal direction, but the present invention can be applied as a vertical type apparatus without any problem.

Further, the resin material as a raw material used in the resin block manufacturing apparatus or manufacturing method of the present invention is not limited to the resin pellets. For example, a resin material obtained by crushing a resin member having an arbitrary shape to reduce its size may be used. Can be used as a raw material.

Further, in the above-described embodiment, an example of manufacturing a resin block or a resin product prototype from one kind of resin pellet (resin material) has been described. However, the raw material of the resin block or the prototype of the resin product is not limited to such a form. For example, one resin block or a resin product prototype may be manufactured using a plurality of types of resin materials such as different types of resin materials and resin materials having different colors as raw materials. In that case, in the step of charging the raw material into the material chamber, the plurality of types of resin materials may be appropriately charged in desired amounts. By operating the resin block manufacturing apparatus in that state as described above, it is possible to manufacture a resin block or a resin product prototype containing a predetermined material in a predetermined ratio or having a desired composition.

Similarly, a resin block or a prototype resin product may be manufactured by mixing a desired additive, a reinforcing material, a metal, or the like with the resin material. A predetermined amount of a desired additive, a reinforcing agent, or the like is put into a material chamber together with a resin material (resin pellet), and a resin block manufacturing apparatus is operated to operate a resin block or a resin containing the predetermined additive or a reinforcing agent. Product prototypes can be manufactured. In the resin block manufacturing apparatus and manufacturing method of the present invention, for example, a resin block or a resin product prototype obtained by adding an arbitrary additive such as a stabilizer such as an antioxidant, a flame retardant, a plasticizer, and an antistatic agent to a resin is used. Can be manufactured. Further, in the resin block manufacturing apparatus and manufacturing method of the present invention, for example, any fibrous reinforcing material such as glass fiber, carbon fiber, aramid fiber, metal fiber, mica, talc, glass flakes, any plate such as a metal plate, etc. Resin block or resin product test in which any reinforcing material or metal object is composited with resin, such as any granular reinforcing material such as shape reinforcing material, silica, calcium silicate, glass beads, carbon black, metal pieces, metal globules, etc. You can make works. A resin block and a resin product prototype containing such an additive, a reinforcing material, etc. manufactured by the production method of the present invention are also within the scope of the present invention.

1, 2 ... Resin block manufacturing equipment 100 ... Material room 102 ... Material storage space 110 ... Rectangular tubular part 110
112 ... Inner peripheral surface 120 ... Material input port 200 ... Gate section 201 ... Material chamber side surface (material chamber end face)
203 ... Mold side surface (mold gate plate side end face)
210 ... Hole 221 ... Resin inflow port (opening on the material chamber side)
222 ... Resin outlet (opening on the resin block molding space side)
230 ... Temperature sensor 250 ... Heater (heating means)
270 ... Cooling unit (cooling means)
271 ... Cooling plate 273 ... Cooling airflow 300 ... Extruded part 320 ... Material Extruded plate 324 ... Extruded plate moving unit 326 ... Extruded plate drive part 400 ... Prototype type part 410 ... Prototype type 411 ... Prototype type base 413 ... Prototype type 1st part 415 ... Prototype Part 2 420 ... Cavity (Prototype molded product growth space)
425 ... Resin flow passage 430 ... Prototype gate opening / closing pin 435 ... Prototype gate opening / closing pin Sliding hole 500, 501 ... Mold part 502 ... Resin block molding space 510, 511 ... Template (side plate)
514 ... Side mold support rod 516 ... Prototype horizontal hole 520 ... Holding plate 521 ... Holding surface 524 ... Holding plate drive rod 526 ... Holding plate driving part 540 ... Mold tension plate (mold part moving means)
544 ... Mold tension plate drive rod (mold part moving means)
546 ... Mold tension plate drive unit (mold unit moving means)
580 ... Extrusion block for mold release 581, 582 ... Plate material 583 ... Rod 584 ... Extrusion block moving part 630, 640 ... Control unit (pressure adjusting means)
RM ... Resin material RB ... Resin block

Claims (14)

A material room that houses the resin material to be supplied, and
A gate portion in which a plurality of holes are formed and arranged on the end face of the material chamber,
A heating means for heating the gate portion and
An extrusion portion that presses the resin material supplied to the material chamber against the heated gate portion and extrudes the melted resin material from the holes.
The resin block molding space for accommodating the extruded resin material is provided, and the volume of the resin block molding space is gradually expanded while applying pressure toward the gate portion to the extruded resin material, and the extruded resin material is said to be extruded. A resin block manufacturing apparatus having a mold portion for integrating a resin material in the resin block molding space. The resin block manufacturing apparatus according to claim 1, further comprising a pressure adjusting means for adjusting a pressure for pushing out the resin material from the hole and a pressure applied to the pushed out resin material toward the gate portion. The resin block manufacturing apparatus according to claim 1 or 2, further comprising a cooling means for cooling the gate portion and the mold portion. The mold is
A side template that defines the side surface of the resin block molding space and has the gate portion arranged on one end side.
It has a holding surface parallel to the gate portion, and has a holding plate that can move in a space surrounded by the side template in a direction perpendicular to the gate portion.
The resin block manufacturing apparatus according to any one of claims 1 to 3, wherein the holding plate is moved to gradually increase the volume of the resin block molding space while applying the pressure to the extruded resin material. A mold portion moving means for moving the side template in a direction perpendicular to the gate portion,
With the side template moved to a position away from the gate portion, it further has a resin block formed inside the side template and an extruded block arranged between the gate portions.
With the extruded block arranged between the resin block and the gate portion, the resin block is moved to the side surface by moving the side mold plate in a direction approaching the gate portion by the mold portion moving means. The resin block manufacturing apparatus according to claim 4, wherein the mold is removed from the template. The resin block manufacturing apparatus according to any one of claims 1 to 5, wherein each of the plurality of holes has a truncated cone shape in which the opening diameter on the resin block molding space side is larger than the opening diameter on the material chamber side. .. The resin block according to any one of claims 1 to 6, further comprising a prototype mold portion having a cavity corresponding to the shape of a desired resin molded product and a resin flow passage connecting the cavity and the resin block molding space. manufacturing device. A prototype mold hole communicating with the resin inflow passage is formed on the inner peripheral surface of the resin block molding space of the mold portion.
The resin block manufacturing apparatus according to any one of claims 1 to 7, further comprising a prototype gate opening / closing pin for controlling a communication state between the cavity and the resin block molding space by opening / closing the prototype hole. The resin block manufacturing apparatus according to any one of claims 1 to 8, wherein the resin material is a resin pellet or a crushed resin. In the resin block manufacturing apparatus according to claim 7 or 8, by applying pressure to the melted resin material accommodated in the resin block molding space, the resin material is made into a prototype portion having a cavity having a desired shape. A resin product manufacturing method for filling the cavity and manufacturing a resin product corresponding to the shape of the cavity. A step of extruding the melted resin material from the holes by pressing the resin material against the gate portion where a plurality of holes are formed and heated.
By gradually expanding the volume of the resin block molding space for accommodating the extruded resin material while applying pressure toward the gate portion to the extruded resin material, the extruded resin material is subjected to the resin block. A resin block manufacturing method that includes a process of integrating in a molding space. The resin block manufacturing method according to claim 11, wherein the pressure applied to the extruded resin material toward the gate portion is smaller than the pressure for extruding the melted resin material from the holes. The resin according to claim 10 or 12, further comprising a step of cooling the resin material integrated in the resin block molding space, wherein the cooling is performed by applying pressure to the resin material toward the gate portion. Block manufacturing method. The resin block manufacturing method according to any one of claims 11 to 13, wherein the resin material is a resin pellet or a crushed resin.

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