JP4808606B2 - Mold and molding method - Google Patents

Description

  The present invention relates to a molding die and a molding method for obtaining a molded product, and particularly to a molding die that can be manufactured easily and inexpensively, and a molding method using the molded product.

  The front cowl of a motorcycle is often made of a resin molded product. With resin molded products, products of various shapes can be molded in large quantities and at low cost.

  A molding die used for obtaining a resin molded product has, for example, a block-shaped synthetic resin as a base and a molding surface that is recessed or bulged in accordance with the surface shape of the molded product.

  On the other hand, in the use of building materials, one using laminated cardboard as a lightweight support base has been proposed (for example, see Patent Document 1).

Utility model registration No.3120150

  In a mold using a synthetic resin block as described above, a considerably large amount of chips are generated when a molding surface is set from a block of blocks, and the waste of material tends to increase.

  Synthetic resin blocks are expensive, and the number of dealers is limited, so availability is not always good. In particular, it is often impossible to determine the suitability of the molding surface unless the molded product is actually molded, and there may be many failures. Therefore, the cost of the synthetic resin block may increase. Moreover, since the synthetic resin block is relatively heavy, it is inconvenient to move and transport.

  On the other hand, what uses the laminated corrugated board like the said patent document 1 is proposed as a support stand, such as building materials, Comprising: The idea and the approach applied to the field | area of a shaping | molding die are not made | formed.

  The present invention has been made in consideration of such problems, and an object thereof is to provide a lightweight and inexpensive molding die that can be easily produced and a molding method using the molding die.

  The mold according to the present invention has the following characteristics.

First feature: a plurality of cardboard (12) base portion are stacked (14) and said base portion is a part of (14), recesses in accordance with the surface shape of the molded article or puffed molding surface (16) have a, plurality of cardboard (12), stage of Shin (22) in each (24) are stacked so as to extend in the same direction, said forming surface (16), said stage (24) It is characterized by being depressed or swollen in the extending direction .

  Thus, by providing a molding surface on the laminated corrugated cardboard, a molding die can be easily produced, and the molding die is lightweight and inexpensive.

In addition , a high-strength mold can be obtained by providing the molding surface in a direction in which the middle shin steps extend in the same direction.

Second feature: The molding surface (16 ) is provided with a resin layer (30) . By providing such a resin layer, the surface of the obtained molded product can be made smoother, and the workability becomes better.

Third feature: The resin layer (30 ) is provided with a hole (32) communicating with the gap (26) of the step (24) . By sucking air from such holes, the work is drawn to the molding surface, and molding can be performed easily.

Fourth feature: It is preferable that the resin layer (30) is an epoxy resin because it has a quick drying property and is easily solidified, and has an appropriate strength after solidification.

  The molding method according to the present invention has the following characteristics.

Fifth feature: a base portion (14) in which a plurality of cardboards (12) are laminated, and a molding surface (16) in which a part of the base portion (14) is recessed in accordance with the surface shape of the molded product A molding method for obtaining the molded product using a molding die (10) comprising: a plurality of corrugated boards (12), each of the middle ridges (22) having a step (24) extending in the same direction. The molding surface (16) is depressed or bulged in the extending direction of the step (24), and the resin layer (30) provided on the molding surface (16) hole (32) is provided which communicates with the gap (26) of the stage (24), said corrugated board (12) the step of at least one of (24) in the gap (26) on the opposite side from the molding surface (16) communicating with the surface, the air from the hole (32) and the gap (26) Wherein the by molding of reluctant workpiece (W) to obtain the molded article.

  In this way, air can be sucked in by effectively using the gap between the steps of the corrugated cardboard, and the work can be drawn to the molding surface, so that molding can be performed easily.

  According to the molding die according to the present invention, a molding die can be easily produced by providing a molding surface on the laminated corrugated cardboard, and the molding die is light and inexpensive.

  In the molding method according to the present invention, suction is performed by effectively utilizing the gap between the steps of the corrugated cardboard, and the work is attracted to the molding surface, so that molding can be performed easily.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a mold and a molding method according to the present invention will be described with reference to FIGS.

  As shown in FIG. 1, a molding die 10 according to the present embodiment includes a base portion 14 in which a plurality of cardboards 12 are laminated, and a molding that is provided on the base portion 14 and is depressed in accordance with the surface shape of the molded product. Surface 16. The molding die 10 is for molding a front cowl part of a motorcycle. It goes without saying that the mold 10 can be applied to various molded products other than the front cowl.

  In the following description, as shown in FIG. 2, the paperboard used for the front and back of the cardboard 12 is the liner 20, the paperboard used for the purpose of forming the corrugated cardboard 12 is the middle shin 22, and each step shape by the middle shin 22. Is a step 24, a gap 26 is provided between each step 24, and a direction parallel to the step 24 is an arrow A direction.

  Returning to FIG. 1, the plurality of cardboards 12 are laminated such that the step 24 of each of the middle ridges 22 extends in the vertical direction. The molding surface 16 is provided so as to be depressed in the direction of the arrow A in which the step 24 extends. A resin layer 30 is provided on the molding surface 16, and the surface is set to be smooth. In the resin layer 30, a plurality of (for example, about four) holes 32 communicating with the 26 gaps are provided at an appropriate distance from each other. The resin layer 30 is thin and sufficient, for example, is set to about 2 to 5 mm. The material of the resin layer 30 is preferably quick-drying, and examples thereof include an epoxy resin. The resin layer 30 is provided such that it slightly protrudes from the entire molding surface 16 and its periphery.

  In FIG. 1, the molding surface 16 (and the molding surface 60 described later) is provided on the surface 14 a in the direction of arrow A in the base portion 14, but depending on the design conditions, the surface 14 b of the liner 20 or the cardboard 12 is laminated. You may provide in the surface 14c of the side currently made.

  Next, a method for creating the mold 10 will be described.

  First, as shown in FIG. 3, a double-sided cardboard 12 is stacked and adjacent liners 20 are bonded together to form a base portion 14. At this time, the intermediate ridges 22 are laminated and bonded so that the steps 24 of the respective shin 22 extend in the same direction. At this time, the corrugated cardboard 12 used is not limited to the double-sided cardboard, but may be a single-sided cardboard, a double-sided cardboard, a double-sided cardboard, or a combination thereof.

  The base unit 14 does not overlap the cardboards 12 one by one, but creates a small block (for example, about 100 mm wide) of a predetermined number in advance, and the small block according to the width of the molding surface 16. You may adhere and create some.

  The base portion 14 thus obtained is lightweight and inexpensive because the cardboard 12 is the base. Further, the base portion 14 has a substantially honeycomb structure by the corrugated cardboard 12, and has a particularly high strength in the direction of arrow A.

  Next, as shown in FIG. 4, the base portion 14 is cut in the direction of arrow A by the cutter 40 to form the molding surface 16. The cutter 40 is preferably controlled by an NC device, for example.

  In this first cutting process, paper chips having a volume corresponding to the molding surface 16 are generated. However, since most of the corrugated cardboard 12 has a gap 26 (see FIG. 2), the actual chips are produced. The volume of is very small. Further, since the chip and the main body block of the base portion 14 are paper, they are effectively reused as waste paper. Since the corrugated cardboard 12 is basically paper, it is very soft as compared with metal, resin, etc., and there is an advantage that the cutter 40 hardly wears.

  In the first cutting process, rough cutting may be performed slightly deeper in consideration of a second cutting process to be performed later.

  By the first cutting process, the molding surface 16 without the resin layer 30 is formed on the base portion 14 as shown in FIG.

  Next, as shown in FIG. 6, a liquid resin 42 is applied to the entire surface of the molding surface 16 and its periphery, and is solidified by heating or natural drying. It is preferable that the resin 42 is an epoxy resin because it has quick drying properties and is easily solidified, and has an appropriate strength after solidification. Further, the epoxy resin before solidification has an appropriate viscosity and does not leak from the gap 26.

  Next, as shown in FIG. 7, as a second cutting step, the resin 42 is cut in the direction of arrow A by the cutter 40 to form the resin layer 30 of the molding surface 16. The cutter 44 is preferably controlled by an NC device, for example. In this case, the resin 42 is formed in an appropriately thin state in advance, and the amount of shavings is very small. In addition, the epoxy resin is easy to cut because it has an appropriate strength.

  The surface of the resin layer 30 thus obtained is set with high accuracy in accordance with the surface shape of the molded product, and the surface of the obtained molded product can be made smoother.

  Next, as shown in FIG. 8, the hole 32 of the arrow A direction is provided in the resin layer 30 with the drill 46 as a drilling process. The hole 32 communicates with the lower surface on the opposite side through the gap 26. Since the resin layer 30 is thin, the amount of shavings when providing the holes 32 is very small, and the hole opening process can be performed easily and quickly.

  A plurality of gaps 26 communicating with one hole 32 may be provided.

  The molding die 10 configured as described above is used as shown in FIG. That is, the gap 26 communicating with the hole 32 is connected to an intake means (not shown) (vacuum pump, ejector, etc.) via the joints 50a, 50b and the tube 52. A workpiece W of a thin plastic plate is placed on the upper surface of the mold 10 and air in a space 56 surrounded by the molding surface 16 and the workpiece W is sucked in by using an intake means. As a result, the workpiece W is sucked in the direction of the arrow A, and a molded product matching the molding surface 16 is obtained by plastic deformation. At this time, the mold 10 receives a force in the direction of arrow A. However, since the strength in the direction of arrow A is high, the mold 10 is hardly deformed, and the molding surface 16 is hardly deformed. Is obtained. Since the mold 10 hardly deforms, it has a long life. Thereafter, if necessary, an excess portion around the molded product may be removed.

  As described above, the mold 10 can be easily made with the corrugated cardboard 12, and is lightweight and inexpensive. In addition, the molding die 10 may not be able to determine the suitability of the molding surface 16 unless the molded product is actually molded. Even in such a case, the material cost can be kept sufficiently low even if the trial production of the mold 10 is repeated several times. Even if it fails, most of the mold 10 can be reused as waste paper.

  Moreover, the number of contractors handling the cardboard 12 is relatively large and the availability is good. Since the corrugated cardboard 12 has an individual plate shape before the base portion 14 is created, it can be easily stored.

  Further, in the molding method using the molding die 10, since the hole 32 communicates with the gap 26 of the step 24 of the corrugated cardboard 12, the gap W is effectively used to perform intake, and the workpiece W is formed on the molding surface. Can be easily formed.

  Next, the molds 10a and 10b according to the modification will be described. In the following description, the same components as those of the mold 10a are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 10, the molding die 10 a according to the first modification is provided with a molding surface 60 swelled in the direction of arrow A at a location corresponding to the concave molding surface 16. The molding surface 60 is set to a shape that swells in accordance with the surface shape of the molded product.

  In such a molding die 10a, the molding die 10 performs molding by sucking air in the space 56 by the intake means, whereas the workpiece W is pressurized from above by a predetermined fluid pressurizing means or the like. It is good to perform molding.

  Further, as shown in FIG. 11, the workpiece W may be molded such that the molding surface 16 of the molding die 10 has a concave shape and the molding surface 60 of the molding die 10a has a convex shape so as to face each other and press. Good.

  Although a detailed description of the procedure for creating the molding die 10a is omitted, when the molding die 10 is created, the cutter 40 is cut so that the molding surface 16 has a concave shape (see FIG. 4). It will be easily understood that the molding die 10a may be cut so that the molding surface 60 has a convex shape.

  As shown in FIG. 12, the molding die 10b according to the second modified example includes a right die 62a and a left die 62b. The molding surface 64a of the right mold 62a and the molding surface 64b of the left mold 62b are opposed to each other in a concave shape, and the portion of the inlet 66 forms a slightly narrow cavity 68.

  In such a mold 10b, for example, the resin material inserted from the inlet 66 by blow molding is deformed so as to contact the cavity 68 by applying a fluid force. The obtained molded product can be taken out after separating the right mold 62a and the left mold 62b. The mold 10b can be suitably used for forming a container, for example.

  In the molds 10, 10a, and 10b, the resin layer 30 is not always necessary, and depending on conditions, the resin layer 30 may be used without the resin layer 30 as shown in FIG. In this case, an arbitrary gap 26 opened in the molding surface 16 can be used for intake.

  The molding die according to the present invention is not limited to the above-described embodiment, and it is needless to say that various configurations can be adopted without departing from the gist of the present invention.

It is a perspective view of the shaping | molding die concerning this Embodiment. It is a partially expanded perspective view of a cardboard. It is a perspective view of the base part obtained by laminating | stacking corrugated cardboard. It is a schematic diagram which shows the mode of a 1st cutting process. It is a perspective view of the base part in which the molding surface without a resin layer was formed. It is a schematic diagram which shows the mode of the process of apply | coating resin. It is a schematic diagram which shows the mode of a 2nd cutting process. It is a schematic diagram which shows the mode of a hole opening process. It is a schematic diagram which shows the mode of shaping | molding by the shaping | molding method which concerns on this Embodiment. It is a perspective view of the shaping | molding die concerning a 1st modification. It is a schematic diagram which shows a mode that press molding is carried out combining the concave and convex molding surfaces. It is a partial cross section perspective view of the shaping | molding die concerning a 2nd modification.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10, 10a, 10b ... Mold 12 ... Corrugated cardboard 14 ... Base part 16, 60, 64a, 64b ... Molding surface 20 ... Liner 22 ... Middle shin 24 ... Step 26 ... Gap 30 ... Resin layer 32 ... Hole

Claims (5)

A base portion (14) in which a plurality of cardboards (12) are laminated;
A molding surface (16) in which a part of the base portion (14) is recessed or bulged in accordance with the surface shape of the molded product;
I have a,
The plurality of corrugated boards (12) are laminated so that the stages (24) of the respective inner shins (22) extend in the same direction,
It said molding surface (16) of the mold, characterized in that extending recesses in the direction or swells in the stage (24) (10). Mold (10) according to claim 1,
A molding die (10) , wherein the molding surface (16) is provided with a resin layer (30 ) . Mold (10) according to claim 2 ,
The mold (10), wherein the resin layer (30) is provided with a hole (32) communicating with the gap (26) of the step (24 ) . Mold (10) according to claim 2 or 3 ,
The mold (10), wherein the resin layer (30) is an epoxy resin. A base portion (14) in which a plurality of cardboards (12) are laminated;
A molding surface (16) in which a part of the base part (14) is recessed in accordance with the surface shape of the molded product,
A molding method for obtaining the molded product using a molding die (10) comprising :
The plurality of corrugated boards (12) are laminated so that the stages (24) of the respective inner shins (22) extend in the same direction,
The molding surface (16) is depressed or bulged toward the extending direction of the step (24),
The resin layer (30) provided on the molding surface (16) is provided with a hole (32) communicating with the gap (26) of the step (24),
Wherein the at least one gap of the stage in the cardboard (12) (24) (26) communicates on the opposite side from the molding surface (16),
A molding method characterized in that the molded product is obtained by molding the workpiece (W) while sucking air from the hole (32) and the gap (26) .

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