JP3244337U - Mold for molding resin materials - Google Patents

Abstract

The present invention provides a mold for molding a resin material that reduces manufacturing costs while improving the efficiency of the curing cycle. [Solution] A mold for molding a resin material includes a plate-shaped molding plate 1 having a molding surface 10 for molding a resin material, and a plurality of supports that support the molding plate on a surface opposite to the molding surface. A support part 2 having plates 21 and 22 is provided. The thickness of the molded plate is either a constant value within the range of 3 mm to 10 mm, or a predetermined range with the median value within the range of 3 mm to 10 mm. The plurality of support plates are arranged in parallel at intervals. The material of the molded plate or the support part is iron, an alloy containing iron, aluminum, an alloy containing aluminum, or an invar alloy. [Selection diagram] Figure 1

Description

The present invention relates to a mold for molding resin materials.

Autoclave molding and RIM molding are methods for molding three-dimensional products using resin materials such as fiber reinforced plastics (FRP). For example, as a mold used in autoclave molding, a mold in which the molding surface of the mold is coated with tetrafluoroethylene resin-dispersed nickel plating has been proposed (see, for example, Patent Document 1).

Japanese Patent Application Publication No. 06-238673

Generally, molds are manufactured from bulk metal materials by machining (bending, welding, cutting, etc.). In particular, when the mold has a three-dimensional shape, it is provided with a thickness, as in the mold described in Patent Document 1, in order to ensure processing accuracy and rigidity of the mold itself. Such molds require a large amount of time to heat and cool, reducing the efficiency of the curing cycle of the molded article. In addition, such a mold requires a large amount of metal material to manufacture the mold, which results in an increase in the weight of the mold and an increase in manufacturing cost.

In view of these circumstances, the present invention aims to provide a mold for molding resin materials that reduces manufacturing costs while improving the efficiency of the curing cycle in molding.

The mold for molding a resin material of the present invention includes a plate-shaped molding plate having a molding surface for molding a resin material, and the thickness of the molding plate is a constant value within the range of 3 mm to 10 mm; or a predetermined range whose median value is within the range of 3 mm to 10 mm.

In the mold for molding a resin material of the present invention, the predetermined range is within a range of ±2 mm with respect to the median value.

The mold for molding a resin material of the present invention further includes a support portion having a plurality of support plates that support the molding plate on a surface opposite to the molding surface, and the plurality of support plates are spaced apart from each other. They are characterized by being arranged in parallel with space between them.

In the mold for molding a resin material of the present invention, at least one of the plurality of support plates is characterized in that the thickness is greater than the thickness of the molding plate.

In the mold for molding a resin material of the present invention, the molding plate is continuous with both the plurality of plate-like regions and the adjacent plate-like regions between the plurality of plate-like regions, and It is characterized by having a joining region that joins the regions.

In the mold for molding a resin material according to the present invention, the plurality of support plates are arranged along a direction perpendicular to a direction in which the plurality of plate-like regions and the coupling regions are arranged.

In the mold for molding a resin material according to the present invention, the material of the molding plate or the support part is any one of iron, an alloy containing iron, aluminum, an alloy containing aluminum, and an invar alloy.

According to the mold for molding a resin material of the present invention, it is possible to achieve the excellent effect of being able to reduce manufacturing costs while improving the efficiency of the curing cycle in molding.

FIG. 1 is a perspective view of a mold in an embodiment of the present invention. (A) and (B) are perspective views of modified examples of the mold in the embodiment of the present invention. FIG. 3 is a perspective view of a support part in an embodiment of the present invention. It is a flowchart of the manufacturing process of the metal mold|die in embodiment of this invention.

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

<Overall configuration of mold>
The mold according to the embodiment of the present invention is mainly used for molding resin materials. Examples of the resin material include fiber reinforced plastic (FRP). Examples of fiber reinforced plastics (FRP) include CFRP and GFRP materials. The molded product is assumed to constitute a part of a flying object such as an aircraft, a rocket, or a space satellite device. In this case, the mold in this embodiment is a mold for an aircraft. Note that the molded product is not limited to one that constitutes a part of the aircraft, and may be other types. As shown in FIG. 1, the mold in this embodiment includes a plate-shaped molding plate 1 and a support portion 2 that supports the molding plate 1.

<Molded plate>
The molded plate 1 will be described below with reference to FIG. 1 and FIGS. 2(A) and 2(B). The molding plate 1 is formed into a plate shape and has a molding surface 10 for molding a resin material. A molded product is molded by placing a resin material on the molding surface 10. The material of the molded plate 1 is assumed to be metal. The metal is preferably iron, an alloy containing iron, aluminum, an alloy containing aluminum, or an invar alloy. Examples of alloys containing iron include steel, but are not limited thereto, and other alloys may also be used. This point also applies below. Further, the thickness of the molded plate 1 may be a constant value (for example, 4 mm) within the range of 3 mm to 10 mm over the entire area of the molded plate 1, or may vary within a predetermined range. . Preferably, the median value of the predetermined range is somewhere in the range of 3 mm to 10 mm (eg, 4 mm). The predetermined range is preferably within a range of ±2 mm with respect to the median value, and more preferably within a range of ±1 mm with respect to the median value. When the thickness of the molded plate 1 is reduced as described above, the heating and cooling time during molding can be shortened, and therefore the efficiency of the curing cycle during molding can be improved. It also contributes to reducing the weight of the mold.

The molded plate 1 may be curved (see FIG. 1) or may be configured in a planar shape. In FIGS. 1 and 2(A), the shape of the molding plate 1 is curved so that the molding surface 10 becomes a concave surface, but the shape is not limited to this, and as shown in FIG. 2(B). As shown, the molding surface 10 may be curved to have a convex surface. In any case, the shape of the molded plate 1 is assumed to be various depending on the shape of the molded product to be the finished product.

Further, the molded plate 1 may be formed of one piece, or may be formed of a plurality of plates joined together by a joining means such as welding. When the curved molded plate 1 is composed of a plurality of plates, the molded plate 1 has a plurality of plate-like regions 12 and a joint region 13, as shown in FIG. 2(A). The bonding region 13 is continuous with both adjacent plate-like regions 12 among the plurality of plate-like regions 12 and couples the adjacent plate-like regions 12 to each other. In FIG. 2(A), the molded plate 1 has three plates (plate-like regions 12) joined together by two bonding regions 13, but this is just an example, and the plates (plate-like regions 12) and The number of bonding regions 13 may be any other number.

<Support part>
The support portion 2 will be described below with reference to FIGS. 1 to 3. As shown in FIGS. 1 and 2A and 2B, the support portion 2 supports the molding plate 1 from a surface 11 opposite to the molding surface 10. As shown in FIGS. The support part 2 is what is called an egg crate. In this embodiment, the support part 2 has a base 20, a plurality of first support plates 21, and a plurality of second support plates 22, which are erected from the base 20, as shown in FIG.

The base 20 is a part that serves as the foundation of the support section 2, and may be formed of a plate-like body or a frame body formed of a plurality of frames. As with the molded plate 1, the material of the base 20 is assumed to be metal. Here, too, the metal is preferably iron, an alloy containing iron, aluminum, an alloy containing aluminum, or an invar alloy. In addition, when the base part 20 is comprised of a plate-shaped body, it may be subjected to a lightening process for the purpose of reducing weight and circulating heat throughout the mold during molding.

Moreover, although the outer edge of the base 20 is configured to have a rectangular shape in this embodiment, it is not limited to this, and may have other shapes. In this embodiment, a case where the base portion 20 has a rectangular shape will be described as an example. As shown in FIG. 3, the direction along one side (long side) of the rectangular base 20 is the X direction, and the direction orthogonal to the X direction in the plane formed by the base 20 is the Y direction (the short side of the rectangular base 20 is The direction perpendicular to both the X direction and the Y direction is defined as the Z direction.

The plurality of first support plates 21 are arranged in parallel with each other at intervals along the X direction, and each first support plate 21 is connected to the base 20 in the Z direction from the base 20. erected in At this time, each first support plate 21 extends in the Y direction and assumes a posture in which the planes of adjacent first support plates 21 face each other. It is preferable that the plurality of first support plates 21 are arranged at equal intervals along the X direction. Further, each of the two first support plates 21 located at both ends in the X direction is arranged at or near the outer edge of the base 20 in the X direction.

The plurality of first support plates 21 support the molding plate 1 on the surface 11 opposite to the molding surface 10. Then, the plurality of first support plates 21 are coupled to the molded plate 1 by a coupling means such as welding. The rigidity of the molded plate 1 is maintained by the support of the plurality of first support plates 21. Although there are 16 first support plates 21 in FIG. 3, the number is not limited to this. The number and arrangement interval of the first support plates 21 are determined in consideration of the rigidity of the molded plate 1.

Further, each of the plurality of first support plates 21 may have a different shape depending on the shape of the molded plate 1. For example, when the molded plate 1 is a curved surface, the support surface 23, which corresponds to the tip end surface of the first support plate 21 and supports the molded plate 1, includes an inclined surface, as shown in FIG. Moreover, when the shape of the molded plate 1 becomes a plane, the support surface 23 of the first support plate 21 does not include an inclined surface. Further, the plurality of first support plates 21 may be subjected to a lightening process for the purpose of reducing weight and circulating heat throughout the mold during molding.

As shown in FIG. 3, the plurality of second support plates 22 support the molding plate 1 on the surface 11 opposite to the molding surface 10, and/or the plurality of first support plates 21 support the molding plate 1 on the side 11 opposite to the molding surface 10. The plurality of first support plates 21 are supported so as not to be tilted toward each other and to maintain the spacing in the X direction. The plurality of second support plates 22 take a posture in which the long sides extend in the X direction and the short sides extend in the Z direction, while intersecting with and adjacent to the plurality of first support plates 21. The second support plates 22 are arranged in parallel at intervals along the Y direction so that their planes face each other. Note that the plurality of second support plates 22 are preferably arranged at equal intervals along the Y direction. Further, each of the two second support plates 22 located at both ends in the Y direction is arranged at or near the outer edge of the base 20 in the Y direction. The plurality of second support plates 22 enter each gap space between adjacent first support plates 21 and engage with each first support plate 21 to maintain the interval between adjacent first support plates 21. play a role. At this time, the plurality of second support plates 22 may be configured to stand upright from the base 20 in the Z direction while being connected to the base 20, or may be configured to be connected to the first support plate 21 while being separated from the base 20. They may be configured to stand up in the Z direction while being connected. Note that the plurality of second support plates 22 may be subjected to a lightening process for the purpose of reducing weight and circulating heat throughout the mold during molding.

In addition, although there are seven second support plates 22 in FIG. 3, the number is not limited to this. The number and arrangement interval of the second support plates 22 are determined in consideration of the rigidity of the molded plate 1 and the first support plate 21.

Since the base 20, the first support plate 21, and the second support plate 22 are configured as described above, the base 20 and the two first supports erected at or near both outer edges of the base 20 in the X direction. A box is constituted by the plate 21 and two second support plates 22 erected at or near both outer edges of the base 20 in the Y direction. The other first support plate 21 and second support plate 22 are arranged inside the box.

Note that the material of the first support plate 21 and the second support plate 22 is assumed to be metal, similarly to the molded plate 1. Here, too, the metal is preferably iron, an alloy containing iron, aluminum, an alloy containing aluminum, or an invar alloy. However, the materials of the molded plate 1, the base 20, the first support plate 21, and the second support plate 22 may be the same or different.

The thickness of at least one of the plurality of first support plates 21 and second support plates 22 is determined in relation to the rigidity of the molded plate 1, but is preferably larger than the thickness of the molded plate 1. . Incidentally, the present invention also includes a case where all of the plurality of first support plates 21 and second support plates 22 are thicker than the molded plate 1. However, if the thickness of the first support plate 21 and the second support plate 22 is made as thin as possible, it will contribute to the weight reduction of the mold. It is preferable that it is not too large compared to the plate thickness.

As described above, since the support part 2 is constituted by a plurality of plates or frames, it contributes to reducing the weight of the mold.

<Mold manufacturing method>
With reference to FIG. 4, a method for manufacturing a mold according to this embodiment will be described. As shown in FIG. 4, there are four steps in manufacturing the mold: a manufacturing process for the molding plate 1, a manufacturing process for the support part 2, a joining process for joining the molding plate 1 and the support part 2, and a final processing process.

In the manufacturing process of the molded plate 1, a material plate to be the material of the molded plate 1 is prepared according to the design data of the molded plate 1. The thickness of the material plate before processing is preferably about 12 to 16 mm, for example. Conventionally, it was common to use a material plate with a thickness of about 20 to 24 mm, but if a thinner material plate than before is used as in this embodiment, the price of the material plate can be reduced. Therefore, as a result, it is possible to reduce the manufacturing cost of the mold.

In addition, when the molded plate 1 has a three-dimensional shape, the molded plate 1 can be divided at a change point of the three-dimensional shape. When the molded plate 1 can be divided at a change point, a plurality of material plates may be prepared in the manufacturing process of the molded plate 1.

Next, the material plate is cut into a desired shape and bent. At this time, bending is performed as necessary while checking the bending accuracy using a dedicated gauge or measuring device.

In addition, when the forming plate 1 is composed of a plurality of material plates, the plurality of bent material plates are placed on a table (temporary header) and formed into a desired shape by a joining means such as welding. Combine each material plate to form one material plate. At this time, the bonding process is performed from the surface 11 opposite to the molding surface 10. In addition, when the forming plate 1 and the support part 2 are joined by welding in the joining process described below, after welding the forming plate 1 and the support part 2, the joining process is performed on each material plate from the forming surface 10 side as well. Welding is performed.

In the manufacturing process of the support part 2, material plates and frame members that are the basis of the base 20, the first support plate 21, and the second support plate 22 are prepared, and the material plates and frame members are subjected to processing such as cutting, A base 20, a first support plate 21, and a second support plate 22 having a desired shape and thickness are manufactured.

Then, the plurality of first support plates 21 are arranged in parallel at intervals along the X direction with the base 20 as a reference, and each first support plate 21 stands up from the base 20 in the Z direction. The plurality of first support plates 21 are coupled to the base 20 by coupling means such as welding. In addition, in a state where each second support plate 22 is erected in the Z direction and engaged with a plurality of first support plates 21 in a posture intersecting the first support plate 21, The second support plates 22 are arranged in parallel at intervals along the line, and the plurality of second support plates 22 are coupled to the first support plate 21 and/or the base 20 by a coupling means such as welding. Thereby, the support part 2 is completed.

Note that the manufacturing process of the molded plate 1 and the manufacturing process of the support part 2 may be performed in any order, or may be performed in parallel at the same time.

In the step of joining the molding surface 10 and the support part 2, the molding plate 1 is placed on the support part 2 so that the surface 11 on the opposite side of the molding surface 10 contacts the support surfaces 23 of the plurality of first support plates 21. Then, the molded plate 1 and the support portion 2 are joined together by a joining means such as welding.

Thereafter, the forming plate 1 is formed so that the thickness thereof becomes a constant value (for example, 4 mm) within the range of 3 mm to 10 mm over the entire area of the forming plate 1, or the forming plate 1 is formed so that the plate thickness is 3 mm to 10 mm. A final processing step is performed that includes processing to form a predetermined range with a median value (for example, 4 mm) within a range of 10 mm. An example of the final processing step is shown below. In the final processing step, first, an unfinished mold in which the molded plate 1 and the support part 2 are combined is subjected to an annealing treatment to relieve stress. Next, the current thickness of the molded plate 1 may be measured using a laser tracker device and the machining allowance based on the desired thickness of the molded plate 1 may be confirmed, but checking of the machining allowance may be omitted. It's okay. Then, cutting is performed on the molded plate 1 to remove an amount corresponding to the machining allowance. After cutting, it may be confirmed by a laser tracker device that the molded plate 1 has a desired thickness, but the confirmation of the plate thickness may be omitted. The mold is completed in the above manner.

It should be noted that the mold of the present invention is not limited to the embodiments described above, and it goes without saying that various changes can be made without departing from the gist of the present invention.

1 Molding plate 2 Support part 10 Molding surface 11 Surface opposite to the molding surface 12 Plate region 13 Bonding region 20 Base 21 First support plate 22 Second support plate 23 Support surface

Claims (7)

Equipped with a plate-shaped molding plate having a molding surface for molding a resin material,
The plate thickness of the molded plate is a constant value within the range of 3 mm to 10 mm, or a predetermined range with a median value within the range of 3 mm to 10 mm.
Mold for molding resin materials. The predetermined range is within a range of ±2 mm with respect to the median value,
A mold for molding a resin material according to claim 1. comprising a support part having a plurality of support plates that support the molding plate on a surface opposite to the molding surface,
The plurality of support plates are arranged in parallel at intervals,
A mold for molding a resin material according to claim 1. At least one of the plurality of support plates has a thickness greater than that of the molded plate,
A mold for molding a resin material according to claim 3. The molded plate is
multiple plate-like areas;
a joint region that is continuous with both of the adjacent plate-like regions among the plurality of plate-like regions and that couples the adjacent plate-like regions;
characterized by having
A mold for molding a resin material according to claim 3. The plurality of support plates are arranged along an orthogonal direction that is orthogonal to the arrangement direction in which the plurality of plate-like regions and the coupling regions are lined up.
A mold for molding a resin material according to claim 5. The material of the molded plate or the support part is any one of iron, an alloy containing iron, aluminum, an alloy containing aluminum, and an invar alloy.
A mold for molding a resin material according to claim 3.

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