JP2599565B2 - Method of forming a mold for forming a molded article, etc., mold obtained by the method, and method of forming a molded article using the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a mold for forming a molded article used for filling and curing a curable raw material and transferring and molding a desired molded article, and a molding material using the same. TECHNICAL FIELD The present invention relates to a method of forming a molded article and a molded article thereof, and particularly to a method of forming a molded article for forming a molded article suitable for projecting and forming the molded article on a concrete wall of a building, a molded article obtained by the method, and a molded article forming method using the same. And a shaped article obtained thereby.

[0002]

2. Description of the Related Art As a material for projecting a shaped object such as a relief on an existing concrete wall of a building, a sheet-shaped or plate-shaped foamed resin material having a certain thickness, a tile shape, a stone shape or the like can be used. (See, for example, Japanese Patent Publication No. 52-142740). The method of using this mold material is to first adhere and temporarily fix one side to the concrete wall surface with nails or double-sided tape, and then fill the hollowed out curable raw material with a spatula or iron from the other side. The desired shaped article having a large thickness is obtained by curing.

[0003] The conventional foamed resin mold has the advantages that a thick molded article can be obtained, and that it is inexpensive and can be crushed and removed from the mold. There are some shortcomings at the time, and it is still not enough. For example, when forming a hollow shape, it is necessary to manufacture a punching blade for the press corresponding to the hollow shape. It is not possible to respond flexibly to on-site design changes in thickness and thickness.

[0004] Further, such a mold member is used by temporarily fixing it to a base such as a concrete wall with a nail or a double-sided tape, but when using a nail, it is quite necessary for an operator to drive the nail into a hard concrete. Not only does it impose a burden, it also leaves nail holes in the underlying concrete surface. In particular, when a nail is used for a resin concrete panel, there is a problem that it is difficult to reuse a resin concrete panel having a nail hole.In addition, the temporary fixing method using a nail may damage a foamed resin material. In some cases, when the curable raw material is filled, the mold material may be displaced, broken, or dropped.

On the other hand, when a double-sided tape is used for temporary fixing, the base surface is not damaged like a nail,
It takes time to peel off the release paper or accurately attach it to the substrate, and the workability becomes extremely poor, especially when working with gloves.

[0006] Further, the conventional shaped article obtained in this way is usually obtained by filling a curable raw material with one piece of mold material and then removing the mold material to obtain a finished product having a single-layer structure. In many cases, the three-dimensionality and change were poor, and the surface was often rough.

[0007]

SUMMARY OF THE INVENTION The present invention has been made by paying attention to such a conventional technique, and can be manufactured at a low cost without the necessity of manufacturing a punching blade for a press. It is an object of the present invention to provide a method for forming a mold material whose thickness can be freely adjusted and a mold material obtained by the method.

Further, the present invention provides a method for forming a molded article having excellent three-dimensionality and surface smoothness, which can efficiently perform temporary fixing without damaging the base surface and the mold material, and a molded article obtained by the method. The purpose is to provide.

[0009]

A method of forming a mold according to the present invention comprises a sheet-shaped or plate-shaped foamed resin having a hollow shape, and one side of the hollow shape forming surface is in close contact with the molded object forming surface. After temporarily fixing, from the other side of the hollow forming surface, a method for forming a mold for projecting a desired molded object on the molded object forming surface by filling and hardening a curable raw material into the hollow shape, A pair of hollow guide plates having a hollow shape of the same shape are respectively applied to two opposing surfaces of a three-dimensional foamed resin block material in a state where the hollow shapes are in the same direction, and the hollow shape of each hollow guide plate is provided. By moving the fusing tool along the edge at the same time, a hollow shape with the same shape as the hollow guide plate is formed in the foamed resin block material. By cutting the fat block material with any thickness, so that mass production of the mold material of the desired thickness.

In this method of forming a molding material, the foamed resin block material is blown off by using the small face of a pair of hollow guide plates as a guide, so that the hollow guide plate can be formed without using a press using a punch blade. The same thing as the hollow shape can be easily and easily formed on the block material.

By simply changing the hollow shape of the hollow guide plate, the hollow pattern of the die can be easily changed, so that it is not necessary to newly manufacture an expensive hollow blade, and small-scale production is possible. And can easily respond to design changes on site.

Further, by cutting this foamed resin block material to an arbitrary thickness using a fusing tool in a direction parallel to the hollow guide plate, a plate-shaped mold material having a desired thickness can be easily obtained. Because it can be mass-produced, the height of the protruding object can be freely adjusted on site. As a result, it is possible to satisfy the demands of reducing equipment costs and transportation costs and significantly shortening the construction period.

Further, the hollow guide plate used for forming the above-described mold material has excellent durability since a heat-resistant material such as a metal tape is applied to the small opening surface of the hollow shape. At the same time, the sliding of the fusing tool such as a nichrome wire is improved. For this reason, it is possible to use not only metal, but also wood, paper, foamed resin, etc. as the material of the hollow guide plate, and it is also possible to reuse the remaining material and waste material generated when the mold material is manufactured become.

Further, the molding of the present invention has a through hole for an anchor formed therein, and a foamed resin stock solution is injected from one side of the through hole, foamed and hardened, and is exposed to the other side. It is temporarily fixed on the forming surface.
That is, if the mold material is brought into close contact with a desired portion of the surface on which the molded object is formed, and a two-component mixed foaming resin stock solution such as polyurethane is injected into the through-hole, the foaming resin stock solution foams and hardens in a few seconds to form the anchor pin. By forming the anchor pin portion exposed on the other side of the through-hole and adhering to the formation object forming surface, the mold material is fixed with an appropriate strength. According to such a method, the mold material can be temporarily fixed instantaneously while closely positioning the mold material on the modeling object forming surface, so that the working efficiency can be greatly improved. If the bonding area is adjusted by appropriately changing the opening size of the through-hole on the side in close contact with the model forming surface, the bonding strength according to the weight of the mold material and the curable raw material filled in the mold material can be obtained.

[0015] After the filled curable raw material is cured and a desired shaped article is obtained, the mold material is crushed and removed.
Since the foam-hardened anchor pin has an appropriate mechanical strength, it can be easily peeled off together with the mold, and after removing the mold, the foam resin adhered to the base surface can be easily scraped off. Therefore, unlike the conventional temporary fixing method using nails or double-sided tape, the surface of the base is not damaged and the working efficiency is not significantly reduced. Such a temporary fixing method is particularly suitable when the base to be temporarily fixed is a resin concrete panel.

The above-mentioned anchor through-hole may be formed in a small size at the opening on the resin injection side, and may be formed in a large size on the side to be adhered to the surface on which the object is formed. According to such a structure, the resin does not protrude toward the resin injection side at the time of resin injection, and the foaming pressure of the resin is easily directed to the bonding surface side, so that a stronger bonding strength can be obtained with a further smaller amount of resin. .

Further, according to the method of forming a molded article according to the present invention, after forming one molded article layer corresponding to this hollowed shape using one mold material, the following molding is performed by using another mold material on this molded article layer. Are formed in layers, and the above-described layer formation is performed an appropriate number of times to form a three-dimensional structure having a multilayer structure.

In such a method of forming a shaped article, since the shaped articles are formed in layers in a stepwise manner, even a large shaped article having a high protruding height can be achieved by using a thin mold material. Is advantageous. In addition, such a method
Since it is not necessary to fill the curable raw material at one time, it is possible to prevent the mold material from shifting or being damaged by its weight.

Still another method of forming a molded article according to the present invention is to form one molded article layer using one molded article having a plurality of hollows formed therein, and then form the same hollow shape as the molded article. The other mold material having the same shape is overlapped and fixed on the one mold material and the modeling object layer at the same position, and by selectively using the hollow shape, it corresponds to the hollow shape on the one modeling material layer. Selectively laminating the next model layer at the location, and further performing such selective lamination formation as appropriate times so as to simultaneously form a plurality of models having different protruding heights. I have.

According to this forming method, even in the case of forming a modeled object having a complicated uneven surface, it is disassembled into a simple plane-shaped object layer and laminated and formed. Become.

Further, in the method of forming a molded article according to the present invention, a surface treatment agent is applied to the surface on which the molded article is formed and the surface of the molded article, then the surface is applied, and the surface finish is performed as an integral molding. The surface finishing agent is for filling and smoothing the gap between the modeling object forming surface and the modeling object, and at the same time filling the gap between the modeling object layers and smoothing the fine irregularities on the modeling object surface. This is for facilitating fixing of the paint. This makes it possible to obtain a modeled object having a smooth surface and an appearance as if integrally molded with the modeled object forming surface.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below.

First Embodiment (FIG. 1)

In this embodiment, a pair of hollow guide plates 2a and 2b each having a hollow shape 1 formed by cutting a 0.5 mm-thick aluminum plate is cut into a three-dimensional block made of styrene foam. Lumber 3
And the block material 3
Is provided with a nichrome wire 4 by drilling in advance. A power source (not shown) is connected to the nichrome wire 4. If the nichrome wires heated by the current from the power source are simultaneously pressed against the small face 5 of each hollow guide plate, a hollow shape is obtained. Block material 3 is cut out in the same shape as 1. After that, when the nichrome wire 4 is also heated and cut into a predetermined width as shown by a two-dot chain line in the figure, the die members 6a, 6b,... Can be

Second Embodiment (FIG. 2)

This embodiment is an example of a hollow guide plate used for forming the above-mentioned mold material. The hollow guide plate 2 uses a plate-shaped styrofoam as a material, and an aluminum strip 7 having the same width as the narrow surface 5 of the hollow shape 1 is arranged on the narrow surface 5 to withstand the heat of the nichrome wire. Like that.

Third Embodiment (FIGS. 3 and 4)

This embodiment relates to a method of temporarily fixing a mold material, and uses a mold material having through holes for anchors formed at four corners. In addition, in order to avoid complication, only one through hole 8 is shown in the figure, and other through holes are omitted. The procedure for forming the through hole 8 is described in, for example, FIG.
As shown in the figure, a shaped plate 9a having a small-sized opening and a shaped plate 9b having a large-sized opening are respectively applied to two opposing surfaces 10a and 10b of the shape member 6, and then similar to the first embodiment. , The circular holes 1 in the plates 9a, 9b
A small through-hole of 1a, 11b is used as a guide to blow off with a nichrome wire 4 to form a tapered through-hole. Then, the mold member 6 is brought into close contact with a desired portion of the concrete wall, and a two-component polyurethane foam resin stock solution is injected into the through hole 8 to fix the mold member 6 in a short time and with appropriate strength.

Fourth Embodiment (FIG. 5)

This embodiment is an example of a case where a three-dimensional modeled object is formed on the surface of a concrete wall by using the above-described mold. In this example, after the first modeling material layer 15 is formed using the first molding material 12, the second molding material 13 is overlapped and temporarily fixed on the first molding material layer 15 at the same position, and the second molding material layer 16 is formed.
Is formed. Further, in the same manner, the third mold member 14 is overlapped, and the third molded object layer 17 is formed, thereby obtaining the molded object 20 projecting in a spire shape. In addition, each molding material may be crushed and removed each time one modeling object layer is formed, but since the modeling object in this example is a layer of a gradually decreasing size of the modeling object layer, Even if the filled curable raw material is cured, if the next mold material is overlaid and temporarily fixed without removing the mold material and temporarily removed after the molded object is completed, the molded object can be formed more stably. In this embodiment, a three-layer model is used. However, it is needless to say that a model having various layers can be formed. If the surface is finished with a cutter or a grinder, it is possible to form a large-sized object entirely composed of a curved surface with a thin mold.

Fifth Embodiment (FIG. 6)

This embodiment is an example in which a three-dimensional structure is formed on the surface of a concrete wall, as in the fourth embodiment, but is constructed so as to surround a space which gradually expands in the order of the layers of the structure. Thus, a shaped object 20 is formed. In this example, the first mold members 12a, 12b
After forming the first modeling object layer 15 by using
a, 12b without removing the second mold 1
The second modeling object layer 16 is formed by overlapping and temporarily fixing the 3a and 13b. Further, the third mold members 14a, 1
4b are overlapped to form a third modeling object layer 17 to obtain a target modeling object 20. Note that the profiles 12b, 13
For b and 14b, the foamed resin stock solution may be adhered to the surface of the concrete wall using the foamed resin stock solution as described above, and in some cases, a through hole may be appropriately provided to inject the foamed resin stock solution.

Sixth embodiment (FIG. 7)

This embodiment is an example in which a three-dimensional structure is formed on the surface of a concrete wall as in the fourth and fifth embodiments. In this example, a plurality of hollow shapes 1a, 1b,
After forming the first modeling object layers 15a, 15b, and 15c using the first mold member 12 on which the first molding material 1c is formed, the first molding material layers 15a, 15b, and 15c are formed.
The second mold member 13 is overlapped at the same position without removing the mold member 12. The second molding 13 has the same hollow shape 1a, 1b, 1c as the first molding 12,
The hollowed-out piece 1a is sealed by fitting and fixing the hollowed-out piece 18a. As a result, the second model layers 16b and 16c are formed, and the third mold 14 is further applied thereon. The third mold member 14 has the same hollow shape 1 as the first mold member 12 and the second mold member 13.
a, 1b, 1c, and the hollow pieces 18a, 18b
The hollowed-out shapes 1a and 1b are sealed by fitting. The third modeling material layer 17c is formed by such a third mold member 14, and a plurality of modeling objects 20a, 20b, and 20c having different protruding heights are simultaneously formed.

Seventh embodiment (FIG. 8 )

This embodiment is an example in which a three-dimensional model is formed basically in the same manner as the fourth and fifth embodiments, but is intended to reduce the weight by making the structure hollow. is there. That is, a desired model 20 having a hollow structure is obtained by appropriately using a mold (not shown) as used in the fourth and fifth embodiments. According to such a structure, even if it is a large modeled object, the weight can be reduced by the internal space, and the amount of the curable raw material used can be reduced.

Eighth embodiment (FIG. 9)

This embodiment is an example in which the surface of a molded article is finished using a surface treating agent. In this example, a primer is applied as a surface treatment agent to the surface of the modeled object forming surface 19 and the surfaces of the modeled object layers 15, 16, and 17 to form the base layer 21, and then the surface is applied to form the coating film 22. doing. Thereby, not only the steps 23 and the gaps 24 but also fine irregularities on the surface of the modeled object are filled, and the modeled object 20 having a smooth surface and integrally molded can be obtained.

[0039]

As described above, the method for forming a mold material according to the present invention and the mold material obtained thereby are formed by fusing and forming a hollow shape using a hollow guide plate. There is no need to manufacture a punching blade for pressing, which is advantageous in terms of cost. In addition, since the shape of the hollow shape and the thickness of the molding material can be easily selected, it is possible to flexibly respond to design changes and small-scale production on site.

Further, in the present invention, since the molding material is temporarily fixed by foaming and hardening of the foamed resin, the molding material can be fixed instantaneously and the base material and the molding material are not damaged as in the case of using a nail. The work load can be greatly reduced as compared with the temporary fixing method.

Further, the method for forming a shaped article according to the present invention comprises:
Since the object layers are stacked, a large object can be obtained by using a thin mold material, and an object having a high degree of three-dimensionality and variation can be obtained.

Furthermore, since the present invention is applied after applying a surface treatment agent to the surface of a molded article, it is possible to easily obtain a smooth surface surface and an appearance similar to integral molding, which were difficult in the past.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of a method for forming a mold according to the present invention.

FIG. 2 is a perspective view showing one embodiment of a hollow guide plate according to the present invention.

FIG. 3 is a partially broken perspective view showing an embodiment of a temporary fixing method according to the present invention.

FIG. 4 is a partially cutaway perspective view showing a method of forming the through holes in FIG. 3;

FIG. 5 is a perspective view showing one embodiment of a method for forming a molded article according to the present invention.

FIG. 6 is a perspective view showing another embodiment of the method of forming a model according to the present invention.

FIG. 7 is a perspective view showing another embodiment of the method of forming a model according to the present invention.

FIG. 8 is a partially broken perspective view showing another embodiment of a molded article according to the present invention.

FIG. 9 is a sectional view showing a state of surface finishing according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Hollow-out type 2 Hollow-out guide plate 3 Block material 4 Fusing tool (Nichrome wire) 5 Small surface 6 Mold material 7 Strip material 8 Through hole 19 Modeling object forming surface 20 Modeling object

Claims (7)

(57) [Claims] 1. A hollow or sheet-like foamed resin having a hollow shape, and one side of a hollow shape forming surface is closely adhered and temporarily fixed on a molded object forming surface, and then the other side of the hollow shape forming surface. A method for forming a mold material for projecting a desired molded object on a molded object forming surface by filling and curing a curable raw material in the hollow shape, forming a pair of hollow guide plates having a hollow shape of the same shape. The hollow shape is oriented in the same direction and applied to the two opposing surfaces of the three-dimensional foamed resin block material, respectively, and along the surface of the heat-resistant material applied to the hollow surface of the hollow shape of each hollow guide plate at the same time. By moving the fusing tool in the state, a hollow shape of the same shape as the hollow guide plate is formed in the foamed resin block material, and then this foamed resin block material is optionally By cutting with a thickness, the method of forming the mold material, characterized in that so as to mass-produce the mold material having a desired thickness. 2. A method for forming a mold according to claim 1.
An obtained mold material, in which a through hole for an anchor is formed, and a foamed resin stock solution is injected from one side of the through hole, foamed and hardened, and is exposed on the other side. Form material temporarily fixed to 3. The molding material according to claim 2 , wherein the through hole for the anchor is formed so that the opening on the resin injection side has a small size and the opening on the side that is in close contact with the surface on which the object is formed has a large size. 4. A molding material according to claim 2 or 3 , wherein a foaming resin stock solution is injected into a through hole for an anchor and foamed and hardened so that the molding material is temporarily fixed on a surface on which a modeled object is formed. Temporary fixing method. 5. A method for forming a molded article using the mold material according to claim 2 or 3 , wherein one molded article layer corresponding to the hollow shape is formed using one mold material. The next three-dimensional structure layer is formed on the three-dimensional structure layer by using another mold material, and a three-dimensional structure having a multilayer structure is formed by performing such a lamination process as necessary. Forming method. 6. A molded object layer is formed by using one molded material having a plurality of hollow shapes formed thereon, and then another mold material having the same hollow shape as the molded material is combined with the one molded material and the molded material. By layering and fixing in place at the same position on the object layer and selectively using the hollow shape, the next model object layer is selectively laminated on this one model layer at the location corresponding to the hollow shape 6. The method according to claim 5, wherein a plurality of formed objects having different protruding heights are simultaneously formed by forming and selectively performing such selective lamination. 7. After applying the surface treatment agent to the surface of the shaped object forming surface and the shaped object is subjected to surface coating, according to claim 5 or 6 and to perform the surface finish of the molded like Method of forming a shaped object.