JP3212581B2 - Method of manufacturing powder shaped article reinforced by chemical bonding of impregnating liquid - 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 of manufacturing a powder shaped article reinforced by chemical bonding of an impregnating liquid, which can rapidly form a powder shaped article having a sufficient practical strength by impregnation with a resin. It is about the method.

[0002]

2. Description of the Related Art Conventionally, in the field of plastic molding and various casting techniques, prior to the final production of a final product, a three-dimensional model formed with a wooden mold or a plaster mold has been prepared, and the moldability and strength of the final product have been prepared. Rough checks such as confirmation and design are widely performed. Especially recently,
In order to shorten the time required to produce a model and reduce costs, a three-dimensional CA
An inexpensive method using a powder molded article molded by the D system has also been proposed.

[0003] However, this inexpensive powder molded product is mainly intended to visually confirm a three-dimensional design shape that is difficult to appear in the drawing, and to check the moldability and strength of the final product. It cannot be performed with high accuracy close to the actual product. In other words, since the powder molded product has a weak bond between the powders and is brittle, it is not possible to investigate the actual state of the fitting state and various functions. When manufacturing a casting mold of silicone or gypsum, there is a problem that it is difficult to release the mold because there are fine irregularities and fine open pores on the outer surface. Also, for example, in the case of a model such as a mold for plastic products, there is a demand to actually mold only a small amount of the final product using this model, but in terms of strength such as heat resistance and durability. There was a problem that it was almost impossible.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and has excellent strength such as sufficient heat resistance and durability. A function test can be performed, and as a resin impregnated powder molding master model, the outer surface is smooth and casting can be easily manufactured, while shortening the manufacturing period and significantly reducing manufacturing costs. The present invention has been completed for the purpose of providing a method for producing a powder molded article impregnated with a resin capable of efficiently producing a powder molded article that can be achieved.

[0005]

Means for Solving the Problems In order to solve the above-mentioned problems, the method of the present invention for producing a powder molded article reinforced by chemical bonding of an impregnating liquid is disclosed. After laying the raw material in a thin layer, a powder coagulation liquid is applied by an ink jet method based on a previously designed pattern on the layer surface to form a powder coagulation layer in which the powder raw material is coagulated into a predetermined pattern. After laying the powder material in a thin layer on the surface of the solidified layer in the same manner as described above, a powder solidified liquid is applied by an ink jet method to form a second powder solidified layer solidified in a predetermined pattern, and thereafter, Is repeated to form a three-dimensional powder coagulated product in which a number of powder coagulated layers are laminated, and then the powder coagulated product is dried, and then impregnated with a thermosetting resin under vacuum. Heat the thermosetting resin below the heat deterioration temperature of It is characterized in.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below. The powder molded article in the present invention is an experimental model, a wooden mold substitute, a simple mold for injection molding, or the like, and is molded by the following procedure. First, a powder raw material made of an organic compound, metal, ceramic, or the like is placed in a saucer-shaped mold having an open upper surface, and the surface is leveled to form a thin layer. Next, a powder coagulation liquid that functions as an adhesive is applied to the surface of this layer to form a powder coagulation layer. At this time, the application of the powder coagulation liquid is performed using a pattern designed in advance using a three-dimensional CAD system or the like. In this manner, a powder solidified layer in a state where the powder raw material is solidified in a predetermined pattern is formed by applying the ink based on the ink jet method.

Next, a powder material is laid in a thin layer of 1 mm or less on the surface of the powder solidified layer in the same manner as described above, and a powder solidified liquid is formed on the surface of the layer based on a previously designed pattern. A second powder solidified layer that is applied by an inkjet method and solidified according to a predetermined pattern is formed. Thereafter, by repeating the same process, a large number of solidified powder solidified layers solidified in a predetermined pattern as designed in advance by a three-dimensional CAD system or the like are laminated and formed to obtain a three-dimensional solidified powder product.

Next, after drying the obtained coagulated powder,
Under a vacuum, a thermosetting resin is sufficiently impregnated into the gaps of the coagulated powder. Thereafter, the resin is sufficiently impregnated by heating to a temperature lower than the thermal deformation temperature of the powder raw material to cure the thermosetting resin, and is excellent in heat resistance and durability, and has no change in shape and conforms to a predetermined size. To obtain a three-dimensional tough powder molded article impregnated with.

In this case, the impregnation of the thermosetting resin is performed under vacuum in order to promote the impregnation of the resin. The vacuum is preferably performed under a vacuum having a degree of vacuum of 4 torr or less. If the degree of vacuum is greater than 4 torr, sufficient resin impregnation will not be performed accurately, and sufficient heat resistance and durability that can withstand practical strength will not be obtained.

[0010] The thermosetting resin to be impregnated includes:
For example, an epoxy resin, a phenol resin, a thermosetting resin such as an unsaturated polyester resin as a main component, and a curing agent such as an aliphatic amine, an aromatic amine, an acid anhydride, and a tertiary amine, Further, if necessary, a diluent or an accelerator to which an appropriate amount is added is used.

Further, gypsum can be used as the powder raw material and a liquid mainly composed of water can be used as the powder coagulating liquid. In this case, the three-dimensional gypsum according to the dimensions set in the three-dimensional CAD drawing is used. The model can be easily obtained in a short time, and since it is impregnated with the resin, it has sufficient mechanical strength, so that a fitting state test or the like can be performed at a level substantially equal to that of an actual product. Further, using silica sand or alumina as a powder raw material, using water glass as a powder coagulation liquid, applying the powder coagulation liquid by an ink jet method, and then forming a powder coagulation layer in a carbon dioxide gas atmosphere. You can also. In this case, the water glass, which is a powder coagulating liquid, is immediately solidified by contact with carbon dioxide gas, so that the sand core can be formed in a shorter time.

[0012]

EXAMPLES (Example 1) A gypsum powder raw material was placed in a mold and the surface was leveled to form a thin layer. Next, a powder coagulating liquid mainly composed of water and a thickener is applied to the layer surface based on a pattern designed based on three-dimensional CAD data in advance by an ink jet method, and the powder raw material is coagulated into a predetermined pattern. A solidified layer was formed. Further, a powder material is laid in a thin layer on the surface of the powder coagulation layer in the same manner as described above, and then a powder coagulation liquid is applied by an inkjet method to form a second powder coagulation layer which coagulates in a predetermined pattern. Thereafter, the same steps were repeated to form a three-dimensional solidified powder product in which a number of solidified powder layers were stacked. Next, after the powder coagulated product was dried, it was impregnated with a thermosetting resin under a vacuum having a degree of vacuum of 4 torr or less. As the resin impregnating liquid, a mixture of 100 parts by weight of an epoxy resin, 124 parts by weight of a curing agent, 20 parts by weight of a diluent, and 2 parts by weight of an accelerator was used. Thereafter, the thermosetting resin was cured by heating at 140 ° C., which is lower than the thermal deterioration temperature of the molded article, for 2 hours to obtain a powder molded article reinforced by chemical bonding of the impregnating liquid. The tensile strength and heat resistance of the obtained powder molded product are sufficient for conducting a practical strength test,
While the conventional product was brittle and collapsed immediately and could not be used for a practical test, the product of the present invention could be subjected to a high-precision strength test or the like before starting the actual production.

(Example 2) In the same manner as in Example 1, a powder molded product reinforced by chemical bonding of an impregnating liquid as a wooden mold substitute was molded. Since the obtained molded article was excellent in tensile strength and heat resistance, it had sufficient performance as a wooden mold substitute.

(Example 3) In the same manner as in Example 1, a powder molded article reinforced by chemical bonding of an impregnating liquid to be an injection mold was molded. Since the obtained molded article was excellent in tensile strength and heat resistance, injection molding of dozens of plastic products could be actually performed using this mold.

[0015]

As is clear from the above description, the present invention has sufficient strength such as sufficient heat resistance and durability, and can perform strength confirmation and various functional tests similar to those of the final product. At the same time, it is possible to efficiently produce a powder molded article capable of shortening the production period and significantly reducing the production cost. Therefore, the present invention greatly contributes to the development of industry as a method for producing a shaped powder product reinforced by chemical bonding of an impregnating liquid that has eliminated the conventional problems.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ identification code FI B29C 33/38 B29C 33/38 (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 67/00 B29C 69/00 -69/02 B29C 70/00-70/88 B29C 9/10 B28B 1/00 B28B 1/30 B29C 33/38

Claims (7)

(57) [Claims] After laying a powder material in a thin layer in a container of a powder molding machine, a powder coagulation liquid is applied to the layer surface by an ink jet method based on a previously designed pattern, and the powder material is applied to a predetermined pattern. A solidified powder layer is formed, and the powder material is laid in the form of a thin layer on the surface of the solidified layer in the same manner as described above. After that, the same steps are repeated to form a three-dimensional powder coagulated product in which a plurality of powder coagulated layers are laminated. Then, after drying the powder coagulated product, Impregnated with a thermosetting resin underneath, and then heated to below the thermal denaturation temperature of the powder raw material to cure the thermosetting resin, characterized by the chemical bonding of the impregnating liquid Production method. 2. The method of claim 1, wherein gypsum is used as a powder raw material, and a liquid mainly composed of water is used as a powder coagulating liquid. 3. The method for producing a powder molded article reinforced by chemical bonding of an impregnating liquid according to claim 1, wherein the powder molded article is an experimental model. 4. The powder shaped product is a wooden mold substitute.
Or a method for producing a powder molded article reinforced by chemical bonding of the impregnating liquid according to 2. 5. The powder reinforced by chemical bonding of the impregnating liquid according to claim 1 or 2, wherein the powder molded article is any one of a simple mold for injection molding, a simple mold for blow molding, and a simple mold for sheet metal pressing. Manufacturing method of body sculpture. 6. The chemical bonding of the impregnating liquid according to claim 1, wherein silica powder or alumina is used as the powder raw material, water glass is used as the powder coagulating liquid, and the powder coagulating layer is formed by carbon dioxide gas. Manufacturing method of powder molded article reinforced by 7. The method for producing a powder molded article reinforced by chemical bonding of an impregnating liquid according to claim 6, wherein the powder molded article is a sand core for a mold.