JP5673364B2 - Release agent coating method and coating apparatus - Google Patents

Release agent coating method and coating apparatus Download PDF

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JP5673364B2
JP5673364B2 JP2011124533A JP2011124533A JP5673364B2 JP 5673364 B2 JP5673364 B2 JP 5673364B2 JP 2011124533 A JP2011124533 A JP 2011124533A JP 2011124533 A JP2011124533 A JP 2011124533A JP 5673364 B2 JP5673364 B2 JP 5673364B2
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release agent
charge amount
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和輝 山村
和輝 山村
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Toyota Motor Corp
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Description

本発明は、離型剤を金型に塗布する方法と塗布装置に関する。特に、静電塗装装置を用いた離型剤塗布方法と塗布装置に関する。   The present invention relates to a method and a coating apparatus for coating a mold release agent on a mold. In particular, the present invention relates to a release agent coating method and coating apparatus using an electrostatic coating apparatus.

塗料を塗布する方法の一つに静電塗装法がある。この方法は、塗装対象を一定の電位(正値、負値、あるいはグランド電位でもよい)に保持しておき、正負逆の電位に帯電させた塗料を吹き付け、電気力によって塗料を対象に吸着させるものである。この静電塗装法は、金型に離型剤を塗布する場合にも利用されることがある(例えば特許文献1)。   One method of applying paint is an electrostatic coating method. In this method, the object to be coated is held at a constant potential (which may be a positive value, a negative value, or a ground potential), the paint charged to a positive or negative potential is sprayed, and the paint is adsorbed to the object by electric force. Is. This electrostatic coating method may also be used when a release agent is applied to a mold (for example, Patent Document 1).

特開平8−215821号公報JP-A-8-215821

静電塗装装置では、予め定められた電圧(あるいは電流)が塗布ノズルに印加されている。ノズルに印加される電圧(電流)によって吐出時の塗料を帯電させる。塗料の帯電量が大きければ塗装対象への吸着力が大きくなる。他方、ノズルと塗装対象の間には電位差があるため、短絡に備えてノズルに印加する電圧(電流)は高くない方が好ましい。このようなトレードオフから、ノズルに印加される電圧(電流)の値は、塗料を塗布するのに必要十分と想定される大きさに設定される。   In the electrostatic coating apparatus, a predetermined voltage (or current) is applied to the coating nozzle. The paint at the time of discharge is charged by the voltage (current) applied to the nozzle. If the charge amount of the paint is large, the adsorption force to the object to be coated becomes large. On the other hand, since there is a potential difference between the nozzle and the object to be coated, it is preferable that the voltage (current) applied to the nozzle in preparation for a short circuit is not high. From such a trade-off, the value of the voltage (current) applied to the nozzle is set to a magnitude assumed to be necessary and sufficient for applying the paint.

ところで近年、金型に塗布する離型剤の体積を極端に少なくする傾向がある。これは、金型表面に塗布される離型剤の膜厚が薄い方が、鋳造品の品質が良くなるからである。具体的には、離型剤が少量になることによりガスの発生が少なくなり、巣穴の発生が抑制できること、離型剤が加熱されることにより生じるいわゆる「焼け」や「湯じわ」の発生が抑制できること、などの品質向上が見込まれる。すなわち、近年では金型に塗布する離型剤の塗布量が、通常の塗料を塗布する場合と比較して極めて少なくなってきている。例えば、1mの金型面積に対して僅か約2cmの離型剤を薄く均一に塗布したい、という要望がある。そのような極めて少量の離型剤を広い面積に塗布するのに静電塗装装置を利用する場合、離型剤(塗料)の吸着力の大きさは非常に重要となる。十分な吸着力があれば、金型表面に薄く均一に離型剤を分散させることができるからである。しかしながら発明者の検討によると、ノズルには適正と思われる電圧(電流)が印加されているはずである従来の静電塗布装置を用いて離型剤を塗布したところ、予想するほどには金型の表面に十分な離型剤が付着しなかった。その原因を調査したところ、ノズルに印加する電圧(電流)の大きさに比較して離型剤の帯電量が小さいことが判明した。即ち、通常の塗料の場合は問題とならなかったが、極めて少量の離型剤を広い面積へ塗布する場合には、従来では十分と考えられていたノズルへの印加電圧(電流)では不十分であるということが判明した。さりとて、ノズルへの印加電圧(電流)をむやみに上げることは、金型とノズルが短絡した場合に好ましからざる結果を招く虞がある。本明細書は、静電塗布方法をベースとしつつ、極めて少量の離型剤を広い面積に塗布するのに好適な技術を提供する。 By the way, in recent years, there is a tendency to extremely reduce the volume of the release agent applied to the mold. This is because the quality of the cast product is improved when the film thickness of the release agent applied to the mold surface is thinner. Specifically, a small amount of mold release agent reduces the generation of gas, can suppress the formation of burrows, and the so-called “burnt” and “water bath” that occurs when the mold release agent is heated. Quality improvement such as being able to suppress the occurrence is expected. That is, in recent years, the amount of the release agent applied to the mold has become extremely small compared to the case of applying a normal paint. For example, there is a demand for applying a thin and uniform release agent of only about 2 cm 3 to a mold area of 1 m 2 . When an electrostatic coating apparatus is used to apply such a very small amount of a release agent over a large area, the magnitude of the adsorption force of the release agent (paint) is very important. This is because the release agent can be dispersed thinly and uniformly on the mold surface if there is sufficient adsorption power. However, according to the inventor's study, when a release agent was applied using a conventional electrostatic coating apparatus in which a voltage (current) that seems to be appropriate should be applied to the nozzle, the gold was as expected. Sufficient mold release agent did not adhere to the mold surface. As a result of investigating the cause, it was found that the charge amount of the release agent was small compared to the magnitude of the voltage (current) applied to the nozzle. In other words, in the case of ordinary paint, there was no problem, but when applying a very small amount of release agent to a large area, the applied voltage (current) to the nozzle, which was conventionally considered sufficient, is insufficient. It turned out that. In the meantime, increasing the applied voltage (current) to the nozzle excessively may cause undesirable results when the mold and the nozzle are short-circuited. The present specification provides a technique suitable for applying a very small amount of a release agent to a large area while being based on an electrostatic application method.

なお、通常の静電塗装装置の中には、ノズルと塗装対象の間の短絡を検知するために電流計が備えられているものがある。その電流計を使えば吹き付けられる塗料の帯電量を推定することはできる。なぜならば、吹き付けられる塗料自体が電荷を運ぶため、この電流計が示す電流は、吹き付けられる塗料の総電荷量を示すことになり、電流計が示す電流の値を吹き付けられる塗料の体積で割れば単位体積当たりの塗料の帯電量を求めることができるからである。しなしながら、発明者の検討によると、塗装対象に届かずに散ってしまう塗料もあるため、従来の静電塗装装置が備える電流計では塗料の帯電量を十分正確に計測することはできないことも判明した。   Some ordinary electrostatic coating apparatuses are equipped with an ammeter for detecting a short circuit between the nozzle and the object to be coated. If the ammeter is used, it is possible to estimate the charge amount of the sprayed paint. Because the sprayed paint itself carries the charge, the current indicated by this ammeter indicates the total charge amount of the sprayed paint, and the current value indicated by the ammeter is divided by the volume of the sprayed paint. This is because the charge amount of the paint per unit volume can be obtained. However, according to the inventor's investigation, there are some paints that do not reach the object to be coated and therefore scatter, so the current meter provided in the conventional electrostatic coating device cannot measure the charge amount of the paint sufficiently accurately. Also turned out.

本明細書が開示する新規な離型剤塗布方法は、静電塗装装置を用いた方法であり、金型への離型剤の塗布に先だって、静電気センサに向けて離型剤を吐出し、吐出された離型剤の単位体積当たりの帯電量が予め定められた規定帯電量以上となるように(好ましくは規定帯電量に一致するように)塗布ノズルに印加する電圧(又は電流)を調整することを特徴とする。規定帯電量は、実験等により事前に定めておく。また、ノズルからの単位時間当たりの吐出量(cm/sec)は、ノズルに離型剤を供給するポンプにおいて計測すればよい(あるいはポンプの能力から推定すればよい)。この方法によれば、金型に塗布する前に離型剤の帯電量が適正であるか否かをチェックすることによって、極めて少量の離型剤を効果的に金型へ塗布することができる。なお、離型剤へ与える帯電量を変えるにはノズルに印加する電圧と電流のいずれを変えてもよいことは明らかである。 The novel release agent coating method disclosed in this specification is a method using an electrostatic coating apparatus, and prior to the application of the release agent to the mold, the release agent is discharged toward the electrostatic sensor, The voltage (or current) applied to the coating nozzle is adjusted so that the charge amount per unit volume of the discharged release agent is equal to or greater than a predetermined charge amount (preferably to match the specified charge amount). It is characterized by doing. The specified charge amount is determined in advance by experiments or the like. In addition, the discharge amount (cm 3 / sec) per unit time from the nozzle may be measured in a pump that supplies the release agent to the nozzle (or may be estimated from the pump capacity). According to this method, it is possible to effectively apply a very small amount of the release agent to the mold by checking whether or not the charge amount of the release agent is appropriate before applying to the mold. . It is obvious that either the voltage or current applied to the nozzle may be changed in order to change the charge amount applied to the release agent.

上記の方法の技術的思想は、次の離型剤塗布装置に具現化することもできる。その装置は、静電塗装装置と、静電気センサと、塗布ノズルへ印加する電圧(又は電流)を調整するコントローラを備える。コントローラは、静電気センサに向けて離型剤を吐出した後、静電気センサによって計測した離型剤の帯電量が予め定められた規定帯電量以上となるように(好ましくは規定帯電量に一致するように)塗布ノズルに印加する電圧(又は電流)を調整する。この離型剤塗布装置は、常に最適な帯電量を有する離型剤を塗布することができる。   The technical idea of the above method can be embodied in the following release agent coating apparatus. The apparatus includes an electrostatic coating apparatus, an electrostatic sensor, and a controller that adjusts a voltage (or current) applied to the coating nozzle. The controller discharges the release agent toward the electrostatic sensor, and then the charge amount of the release agent measured by the electrostatic sensor is equal to or greater than a predetermined specified charge amount (preferably to match the specified charge amount). Ii) Adjust the voltage (or current) applied to the coating nozzle. This release agent coating apparatus can always apply a release agent having an optimum charge amount.

離型剤塗布装置の概略図を示す。The schematic of a mold release agent coating device is shown. 塗布量と帯電量の変化を示すグラフである。It is a graph which shows the change of application amount and charge amount.

図1に、離型剤塗布装置10の全体図を示す。離型剤塗布装置10は、ノズル2、ポンプ3、タンク4、電源5、コントローラ6、及び、静電気センサ7を備える。離型剤は、タンク4に蓄えられ、ポンプ3でノズル2へと送られる。ノズル2には、電源5から所定の電圧が印加される。ノズル2に達した離型剤は、ノズル2から吐出する際、ノズル2に加えられた電圧によって所定の電位に帯電する。ノズル2、ポンプ3、タンク4、電源5で構成される装置自体は、従来の静電塗布装置と同じである。   FIG. 1 shows an overall view of a release agent coating apparatus 10. The release agent coating apparatus 10 includes a nozzle 2, a pump 3, a tank 4, a power supply 5, a controller 6, and an electrostatic sensor 7. The release agent is stored in the tank 4 and sent to the nozzle 2 by the pump 3. A predetermined voltage is applied to the nozzle 2 from the power supply 5. The release agent that has reached the nozzle 2 is charged to a predetermined potential by the voltage applied to the nozzle 2 when discharged from the nozzle 2. The apparatus itself composed of the nozzle 2, the pump 3, the tank 4, and the power source 5 is the same as a conventional electrostatic coating apparatus.

静電気センサ7は、離型剤の塗布対象である金型MDの脇に設置される。静電気センサ7と金型MDは電気的に接地させ、グランド電位にしておく。即ち、静電気センサ7と金型MDは同じ電位にしておく。静電気センサ7は、対象の電位を計測することができるセンサであり、その仕組みの一例は、そのセンサヘッドに内蔵された表面電位センサに電圧を一定範囲内で階段状に変化させながら印加し、電圧が0Vとなるポイントを内部演算で算出することによって対象の電位を特定する。内部演算により算出された電圧が0Vとなったときに印加していた電圧が、静電気量の測定対象(本実施例の場合は離型剤)の電位に相当する。   The electrostatic sensor 7 is installed beside the mold MD that is a target for application of the release agent. The electrostatic sensor 7 and the mold MD are electrically grounded and kept at the ground potential. That is, the electrostatic sensor 7 and the mold MD are kept at the same potential. The electrostatic sensor 7 is a sensor that can measure the potential of an object. An example of the mechanism is to apply a voltage to a surface potential sensor built in the sensor head while changing the voltage stepwise within a certain range. The target potential is specified by calculating the point at which the voltage becomes 0 V by internal calculation. The voltage applied when the voltage calculated by the internal calculation becomes 0 V corresponds to the potential of the electrostatic quantity measurement object (release agent in this embodiment).

ユーザは金型MDへの離型剤の塗布に先だって、吐出させる離型剤の単位体積当たりの帯電量の調整を行う。ユーザはまず、静電気センサ7に向けて離型剤を吐出させる(図1の矢印A)。静電気センサ7に向かって離型剤を吐出させている間、静電気センサ7は定期的に表面電位センサに付着した離型剤の電圧を計測し、コントローラ6へ送る。コントローラ6には、また、単位時間当たりの離型剤の吐出量も入力される。単位時間当たりの吐出量は、ポンプ3に備えられた流量計によって計測される。コントローラ6は、単位時間当たりの離型剤の吐出量と、静電気センサ7の計測値から離型剤の単位体積当たりの帯電量を算出する。コントローラ6は、離型剤の単位体積当たりの帯電量が予め定められた規定帯電量に一致するように(あるいは規定帯電量以上となるように)、電源5が印加する電圧を調整する。調整が終了したら、ユーザはノズル2を金型MDへ向け、離型剤を塗布する(図1の矢印B)。金型MDと同電位にした静電気センサ7を金型MDの横に配置することには、帯電量の調整が完了したら直ちに金型MDへの塗布を行える利点がある。   Prior to application of the release agent to the mold MD, the user adjusts the charge amount per unit volume of the release agent to be discharged. First, the user discharges the release agent toward the electrostatic sensor 7 (arrow A in FIG. 1). While discharging the release agent toward the electrostatic sensor 7, the electrostatic sensor 7 periodically measures the voltage of the release agent adhering to the surface potential sensor and sends it to the controller 6. The controller 6 is also input with a discharge amount of the release agent per unit time. The discharge amount per unit time is measured by a flow meter provided in the pump 3. The controller 6 calculates the charge amount per unit volume of the release agent from the discharge amount of the release agent per unit time and the measured value of the electrostatic sensor 7. The controller 6 adjusts the voltage applied by the power source 5 so that the charge amount per unit volume of the release agent matches a predetermined charge amount (or more than the specified charge amount). When the adjustment is completed, the user directs the nozzle 2 toward the mold MD and applies a release agent (arrow B in FIG. 1). Disposing the electrostatic sensor 7 having the same potential as the mold MD beside the mold MD has an advantage that the mold MD can be applied immediately after the adjustment of the charge amount is completed.

図2を参照して、帯電量調整のアルゴリズムを説明する。図2は、ノズル2から吐出され、静電気センサ7の表面へ到達した離型剤の体積(吐出量)と、静電気センサ7によって計測された電圧の関係を示すグラフである。今、時刻t1に塗布を開始し、時刻t2で塗布を終了したと仮定する。離型剤のノズル2からの吐出量は、a1[cm/sec]であるとする。時刻t1からt2まで、時間Tの間に静電気センサ7に吹き付けられる離型剤の体積A1[cm]は、A1=a1×Tで表せられる。時刻t2において静電気センサ7の計測した電圧がV1である場合、離型剤の単位体積当たりの帯電量Qは、Q=V1/A1=V1/(a1×T)[V/cm]で求まる。なお、帯電量の単位は[C](クーロン)で表すこともできるが、ここでは[V](ボルト)の単位で表すことにする。静電気センサ7の出力が[V]で表されるので、その方が便利だからである。コントローラ6は、単位体積当たりの帯電量Qが予め定められた規定帯電量Qdよりも小さい場合、電源5を制御し、ノズル2への印加電圧を上げる。コントローラ6は、ノズル2から吐出する離型剤の単位体積当たりの帯電量Qが規定帯電量Qd以上となるまでノズル2へ印加する電圧を高める。ノズル2から吐出する離型剤の単位体積当たりの帯電量Qが規定帯電量Qdに一致すると(あるいは規定帯電量以上となると)、コントローラ6はその旨を示す信号(ブザー音あるいは表示ランプ)を出力し、離型剤の帯電量Qが規定帯電量Qdまで上昇したことをユーザに知らせる。通知を受けたユーザはノズル2を金型MDに向け、離型剤の金型への塗布を開始する。なお、規定帯電量Qdは予め実験等により定められ、コントローラ6に記憶されている。 The charge amount adjustment algorithm will be described with reference to FIG. FIG. 2 is a graph showing the relationship between the volume (discharge amount) of the release agent discharged from the nozzle 2 and reaching the surface of the electrostatic sensor 7 and the voltage measured by the electrostatic sensor 7. Now, it is assumed that application starts at time t1 and application ends at time t2. The discharge amount of the release agent from the nozzle 2 is assumed to be a1 [cm 3 / sec]. From time t1 to time t2, the volume A1 [cm 3 ] of the release agent sprayed on the electrostatic sensor 7 during the time T is expressed by A1 = a1 × T. When the voltage measured by the electrostatic sensor 7 at time t2 is V1, the charge amount Q per unit volume of the release agent is obtained by Q = V1 / A1 = V1 / (a1 × T) [V / cm 3 ]. . The unit of the charge amount can be expressed by [C] (Coulomb), but here, it is expressed by the unit of [V] (Volt). This is because the output of the electrostatic sensor 7 is represented by [V], which is more convenient. When the charge amount Q per unit volume is smaller than a predetermined charge amount Qd, the controller 6 controls the power supply 5 to increase the voltage applied to the nozzle 2. The controller 6 increases the voltage applied to the nozzle 2 until the charge amount Q per unit volume of the release agent discharged from the nozzle 2 becomes equal to or greater than the specified charge amount Qd. When the charge amount Q per unit volume of the release agent discharged from the nozzle 2 coincides with the specified charge amount Qd (or when it exceeds the specified charge amount), the controller 6 sends a signal (buzzer sound or display lamp) indicating that fact. To inform the user that the charge amount Q of the release agent has increased to the specified charge amount Qd. The user who has received the notification directs the nozzle 2 toward the mold MD and starts applying the release agent to the mold. The specified charge amount Qd is determined in advance by experiments or the like and stored in the controller 6.

上記の離型剤塗布装置10によれば、ノズル2から吐出する離型剤の帯電量を常に規定帯電量以上に管理することができる。すなわち、離型剤の金型表面への吸着のし易さを一定に維持することができる。上記の離型剤塗布装置10は、従来の静電塗装方法をベースにしているが、極めて少量の離型剤を広い面積に塗布するのに優れている。   According to the release agent coating apparatus 10 described above, the charge amount of the release agent discharged from the nozzle 2 can always be managed to be equal to or greater than the specified charge amount. That is, the ease of adsorption of the release agent to the mold surface can be kept constant. The release agent coating apparatus 10 is based on a conventional electrostatic coating method, but is excellent in applying a very small amount of the release agent over a wide area.

上記した離型剤塗布装置10の留意点を述べる。静電気センサ7は、計測するたびに除電する必要がある。即ち、付着した離型剤を払拭するとともに、計測値をゼロにリセットする。また、実施例の離型剤塗布装置10では、吐出する離型剤の単位体積当たりの帯電量が規定帯電量となるように、ノズル2に印加する電圧を調整したが、電圧に代えてノズル2に印加する電流の大きさを調整してもよい。ノズル2に印加する電圧が一定であっても電流の大きさを変えることによって、離型剤に与える帯電量を変えることができるからである。   Points to be noted of the release agent coating apparatus 10 described above will be described. The electrostatic sensor 7 needs to be neutralized every time it measures. That is, the attached release agent is wiped off and the measured value is reset to zero. Further, in the release agent coating apparatus 10 of the example, the voltage applied to the nozzle 2 is adjusted so that the charge amount per unit volume of the release agent to be discharged becomes the specified charge amount. The magnitude of the current applied to 2 may be adjusted. This is because the amount of charge applied to the release agent can be changed by changing the magnitude of the current even if the voltage applied to the nozzle 2 is constant.

以上、本発明の具体例を詳細に説明したが、これらは例示に過ぎず、特許請求の範囲を限定するものではない。特許請求の範囲に記載の技術には、以上に例示した具体例を様々に変形、変更したものが含まれる。本明細書または図面に説明した技術要素は、単独であるいは各種の組合せによって技術的有用性を発揮するものであり、出願時請求項記載の組合せに限定されるものではない。また、本明細書または図面に例示した技術は複数目的を同時に達成し得るものであり、そのうちの一つの目的を達成すること自体で技術的有用性を持つものである。   Specific examples of the present invention have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the specific examples illustrated above. The technical elements described in this specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technology exemplified in this specification or the drawings can achieve a plurality of objects at the same time, and has technical usefulness by achieving one of the objects.

2:ノズル
3:ポンプ
4:タンク
5:電源
6:コントローラ
7:静電気センサ
10:離型剤塗布装置
2: Nozzle 3: Pump 4: Tank 5: Power supply 6: Controller 7: Electrostatic sensor 10: Release agent coating device

Claims (2)

静電塗装装置を用いた金型への離型剤の塗布方法であり、
金型への離型剤の塗布に先だって、静電気センサに向けて離型剤を吐出し、静電気センサによって計測された離型剤の帯電量が予め定められた規定帯電量以上となるように塗布ノズルに印加する電圧又は電流を調整することを特徴とする離型剤塗布方法。
It is a method of applying a release agent to a mold using an electrostatic coating device,
Prior to the application of the release agent to the mold, the release agent is discharged toward the electrostatic sensor, and applied so that the charge amount of the release agent measured by the electrostatic sensor is greater than or equal to a predetermined charge amount. A release agent coating method comprising adjusting a voltage or a current applied to a nozzle.
静電塗装装置と、
静電気センサと、
静電気センサに向けて離型剤を吐出した後、静電気センサによって計測された離型剤の帯電量が予め定められた規定帯電量以上となるように静電塗装装置の塗布ノズルに印加する電圧又は電流を調整するコントローラと、
を備えることを特徴とする離型剤塗布装置。
Electrostatic coating equipment,
An electrostatic sensor,
After discharging the release agent toward the electrostatic sensor, the voltage applied to the coating nozzle of the electrostatic coating apparatus so that the charge amount of the release agent measured by the electrostatic sensor is equal to or greater than a predetermined charge amount or A controller for adjusting the current;
A mold release agent coating apparatus comprising:
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