JP5981743B2 - Manufacturing method of electroforming mold for building materials - Google Patents

Description

  The present invention relates to a method for manufacturing an electroforming mold used for press molding of a building material.

  2. Description of the Related Art Conventionally, it is known that a building material having a concavo-convex pattern is produced by pressing a surface of a building material with a press mold. By forming the concavo-convex pattern, a building material excellent in appearance design can be obtained.

  Resin molds, molds, and the like exist as press molds, but molds are suitable for production of building materials. This is because the resin mold is easy to manufacture and easy to process, but if it is used repeatedly, it will be worn out and the mold shape cannot be maintained.

JP 2009-190307 A

  Examples of the mold include a mold obtained by manually processing a metal material, an etching mold obtained by etching a metal material, and an electroformed mold formed by electroforming plating.

  As a mold that is manually processed, a mold that is formed by cutting, polishing, and removing a metal is known as a general method. However, this method requires a fine polishing operation by a person, and requires a skillful technique to form a concavo-convex pattern with high accuracy, and a mold cannot be easily produced.

  The etching mold is for forming a masking film based on the shape of the master model, corroding the metal mold material, and forming an uneven pattern. Etching molds can form shallow and fine patterns uniformly, and the amount of wear is small, but there are steps, so manual finishing by humans is necessary, and there is a difference in pattern from the master model. Occur.

  On the other hand, an electroforming mold is formed by electroforming plating using a transfer plating base material that matches the shape of the prototype made by the prototype resin mold. Can be produced. Therefore, it is conceivable to use an electroformed mold as a mold for building materials.

  Although the method of patent document 1 is disclosed as a manufacturing method of an electroforming metal mold | die, this method is not related with metal mold | die manufacture peculiar to building materials. Therefore, a mold manufacturing method suitable for the use of building materials is desired.

  In building materials, the appearance formed by the uneven pattern on the surface is an important element, and such an appearance is not only numerical data, but a prototype is created to check what kind of appearance actually occurs. It is required to modify the original data to produce a final product mold.

  FIG. 4 is an example of a method for producing an electroforming mold A for building materials.

  In producing the electroforming mold A for building material, as shown in FIG. 4A, first, the building material 2 is produced by press-molding the building material with the prototype resin mold 1. The prototype resin mold 1 is formed by cutting based on the uneven pattern data of the building material to be produced. The prototype resin mold 1 is supported by a base substrate 7 and attached to a press machine 8. Next, as shown in FIG. 4B, the shape of the prototype resin mold 1 is corrected based on the shape of the prototype building material 2. At this time, the shape of the surface of the prototype building material 2 that has been press-molded is confirmed, the shape of the prototype resin mold 1 is adjusted and finely adjusted, and further press molding is performed on the surface of the prototype building material 2. Repeat the process of checking the shape. Then, the shape of the prototype resin mold 1 is corrected so that the prototype building material 1 to be press-molded satisfies the required specifications and has a desired shape. For example, the shape of the concave portion 1 a and the convex portion 1 b of the prototype resin mold 1 is corrected from the shape of the convex portion 2 a and the concave portion 2 b of the prototype building material 2. Next, as shown in FIG. 4C, a transfer model 4 is produced based on the shape of the prototype resin mold 1 whose shape has been corrected. In the transfer model 4, the unevenness of the prototype resin mold 1 is transferred to the surface of the transfer model 4. Next, as shown in FIG. 4 (d), the electroformed plating part 5 is formed by performing electroforming plating on the surface of the transfer model 4. Then, as shown in FIG. 4 (e), the electroformed plating part 5 is released from the transfer model 4 and joined to the backup material 6. The backup material 6 is supported by a base substrate 7 for attachment to the press machine 8. The electroformed mold A formed in this way is attached to the press 8 and can be used for production of building materials.

  However, the method shown in FIG. 4 has the following problems. Although the prototype resin mold 1 is formed by cutting, the material of the prototype resin mold 1 is required to have performances such as strength, heat resistance, and oil resistance that are not damaged by press molding. Therefore, the prototype resin mold 1 is given priority to the required performance at the time of press molding. Therefore, a material optimized for cutting workability cannot be used, and processing burrs, processing marks, and the like often occur. In that case, long time finishing is required manually to remove the processing burrs and processing marks before the transfer model 4 is manufactured, and the electroforming mold A cannot be manufactured efficiently.

  There are also the following problems. When correction processing of the shape of the prototype resin mold 1 occurs many times, the difference in shape between the corrected portion and the uncorrected peripheral portion is inherited by the electroforming mold A for production, and the design properties of the building material are impaired. It will be. In addition, since the prototype resin mold 1 has a fast progress in wear, when the number of prototypes increases, a pattern change due to wear occurs, and this pattern change is inherited by the electroforming mold A, thereby impairing the design of the building material. . Further, there is a problem that the deformation amount of the building material at the time of press molding differs between the prototype resin mold 1 and the production electroforming mold A, and the pattern depth and the appearance differ between the prototype and the product. . The difference in the amount of deformation occurs in the building material due to the difference in the mold material between the resin and the metal, and this difference appears as an error in the pattern depth.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to accurately and efficiently manufacture an electroforming mold for building materials.

The manufacturing method of an electroforming mold for building material according to the present invention is to produce a prototype building material by press molding a building material with a prototype resin mold, and correct the shape of the prototype resin mold based on the shape of the prototype building material Then, based on the prototype resin mold whose shape has been corrected, the master mold is manufactured by correcting the shape of the prototype resin mold so as to approach the shape of the target building material, and the correction is an adjustment correction or a dimension correction. A transfer model is produced based on the shape of the master mold, an electroformed plating part is formed by electroforming plating on the surface of the transfer model, and the electroformed plating part is released from the transfer model. It is characterized by this.
In the above-described method for manufacturing an electroforming mold for building materials, the correction is preferably a pattern change correction.
In the above method for producing an electroforming mold for building materials, the master mold is preferably made of a resin having a higher hardness than the prototype resin mold.

  ADVANTAGE OF THE INVENTION According to this invention, the electrocast metal mold | die for building materials can be manufactured accurately and efficiently.

An example of embodiment of the manufacturing method of the electroforming metal mold | die for building materials is shown, (a)-(f) is sectional drawing. It is sectional drawing explaining the deformation amount of the building material at the time of press molding. It is a perspective view which shows an example of a building material. An example of the manufacturing method of the electroforming metal mold | die for building materials is shown, (a)-(e) is sectional drawing.

The manufacturing method of the electrocasting die A for building materials of the present invention sequentially goes through the following steps.
The building material 2 is produced by press-molding the building material with the prototype resin mold 1.
-The shape of the prototype resin mold 1 is corrected based on the shape of the prototype building material 2.
A master mold 3 is produced based on the prototype resin mold 1 whose shape has been corrected.
A transfer model 4 is produced based on the shape of the master mold 3.
The electroformed plating part 5 is formed by performing electroforming plating on the surface of the transfer model 4.
-The electroformed plating part 5 is released from the transfer model 4.

  FIG. 1 is an example of a manufacturing method of an electroforming mold A for building materials. As shown in FIG. 1A, first, a building material 2 is produced by press-molding a building material with a prototype resin mold 1.

  As the building material, for example, a cement-based material can be used. The cement-based material is a material prepared by adding water and appropriate additives to the cement and mixing them. As the cement, Portland cement, blast furnace cement, or the like can be used. Moreover, as an additive, an aggregate, a lightweight aggregate, a reinforcing fiber, a water reducing agent, a thickener, etc. can be used. It is preferable that the building material is usually in a green sheet state in advance by extrusion molding or papermaking. By pressing the green sheet, the uneven pattern can be easily transferred. The building material used for the trial production is preferably the same as the building material used for the production of building materials. Thereby, the prototype building material 2 can be produced under the same conditions. However, you may use the building material which remove | excluded or substituted the one part component which does not affect the shape of an uneven | corrugated pattern, or has little influence. Thereby, even when the composition and specifications of the building material are changed, it is not necessary to make a new prototype.

  The prototype resin mold 1 is a formwork for producing a prototype building material 2 that is a prototype of a building material by imparting a concavo-convex pattern to the surface by pressing the building material. By using the resin, the processing is simplified and the shape can be easily corrected. The resin mold can be easily produced by molding a resin.

  The prototype resin mold 1 is produced based on pattern data (basic data). The pattern data may be obtained by digitizing the data of the uneven pattern on the surface of the building material to be manufactured.

  In general, the resin mold includes a cast resin mold and a processed resin mold. The casting resin mold is one in which a resin is poured into a mold material serving as a master model to form an uneven pattern. In the casting resin mold, a pattern can be formed faithfully to the master model shape. Further, the processed resin mold is for forming a concavo-convex pattern by cutting a resin material based on data obtained by digitizing the concavo-convex shape. In the processed resin mold, the pattern surface can be formed with high accuracy. Further, the shape can be easily changed by data editing. Among these, as the prototype resin mold 1, it is preferable to use a processed resin mold having high processability. Thereby, the shape of the prototype building material 1 can be easily corrected.

  As a material of the prototype resin mold 1, a polyurethane resin, an epoxy resin, or the like can be used.

  The prototype resin mold 1 is formed of a material having performance such as strength, heat resistance, and oil resistance that is not damaged by press molding. In particular, it is preferable that the material is not damaged even if it is press-molded a plurality of times. As a result, a plurality of building material prototypes can be prototyped with the prototype resin mold 1, and the shape of the mold surface can be adjusted with high accuracy.

  Moreover, since the shape of the prototype resin mold 1 is modified by cutting or polishing, it is preferable to use a soft resin having a low hardness. If the hardness is high, processing may be difficult.

  Press molding using the prototype resin mold 1 is performed by a press machine 8. At this time, it is preferable to carry out under the same conditions as in production. By performing under the same conditions as at the time of production, it is possible to apply the same load to the building material, and it is possible to produce a highly accurate mold with little error between the prototype and the product. Therefore, more preferably, the same press machine 8 as the press machine 8 used in production is used. Moreover, it is preferable that the conditions of temperature, pressure, and holding time in press molding are the same as in production. The temperature of the press molding may be room temperature or a heating temperature (for example, 60 to 100 ° C.) by so-called hot pressing. The pressure for press molding can be, for example, in the range of 1 to 10 MPa, but is not limited thereto. The press holding time can be, for example, in the range of 1 to 30 seconds, but is not limited thereto. The press machine 8 can use a general purpose thing.

  By pressing with the prototype resin mold 1, the surface of the prototype building material 2 is provided with an uneven pattern. The uneven pattern may be a pattern having joint grooves.

  FIG. 3 is an example of the prototype building material 2. The shape of the prototype building material 2 is roughly the same as the building material to be produced. This building material is a building board 10 used as an outer wall material or the like. The building board 10 is formed in a rectangular shape, and is used by being vertically and horizontally attached to a wall. The building board 10 is provided with a plurality of linear joint grooves 12 vertically and horizontally, and a portion sandwiched between the joint grooves 12 protrudes to form a plurality of rectangular protrusions 11 arranged vertically and horizontally. Yes. By obtaining the building board 10 having such joint grooves 12, a brick-like or masonry-like outer wall can be formed from the building board 10. The uneven pattern obtained by press molding may be an uneven pattern having a relatively large uneven width (thickness) such as the joint groove 12 and the convex portion 11. In addition, the fine uneven | corrugated pattern of the depth shallower than the depth of the joint groove 12 may be provided to the convex part 11 on the surface of the building board 10. The concavo-convex pattern obtained by press molding may be a fine concavo-convex pattern that is formed on the surface of the convex portion 11 and expresses a texture.

  As shown in FIG. 1 (a), since the prototype resin mold 1 is for transferring a concavo-convex pattern, the irregularities are reversed from the prototype building material 2, and the convex portion 2a of the prototype building material 2 is the prototype resin mold. Corresponding to the concave portion 1 a of 1, the concave portion 2 b of the prototype building material 2 corresponds to the convex portion 1 b of the prototype resin mold 1. In the building board 10 of FIG. 3, the convex part 2 a and the concave part 2 b of the prototype building material 2 constitute the convex part 11 and the joint groove 12 of the building board 10. That is, the concave portion 1 a of the prototype resin mold 1 forms the convex portion 11 of the building board 10, and the convex portion 1 b of the prototype resin mold 1 forms the joint groove 12 of the building board 10. When the surface of the building board 10 has a fine uneven pattern, the uneven shape of the prototype resin mold 1 is an inverted shape corresponding to the uneven pattern of the building board 10. In this embodiment, it is possible to obtain an electroformed mold A capable of producing a building material on which such an uneven pattern is formed.

  Next, as shown in FIG. 1B, the shape of the prototype resin mold 1 is corrected based on the shape of the prototype building material 2 to obtain the prototype resin mold 1 after the shape correction. In correcting the shape of the prototype resin mold 1, the shape of the concavo-convex pattern on the surface of the prototype building material 2 is evaluated. That is, when used as a building material, it is confirmed whether or not the prototype building material 2 is provided with a concavo-convex pattern that constitutes the target appearance. If the shape of the prototype building material 2 does not match the target shape, the prototype resin mold 1 is used so that the shape of the prototype building material 2 to be press-molded matches the target shape. To correct the shape. For example, when manufacturing the building board 10 as shown in FIG. 3, the protruding height of the convex portion 11, the groove depth of the joint groove 12, the corner portion 11a of the convex portion 11, the corner portion 11b of the convex portion 11, etc. The prototype resin mold 1 can be modified so that the shape becomes the desired shape.

  The shape of the prototype resin mold 1 can be corrected by cutting or polishing. Cutting can be performed using a cutter or the like. The polishing process can be performed using a file or the like.

  The uneven shape of the prototype resin mold 1 is a shape obtained by inverting the uneven shape of the prototype building material 2. Therefore, when it is desired to further protrude the convex portion 2a of the prototype building material 2, the concave portion 1a that is a corresponding portion of the prototype resin mold 1 may be further scraped off. Moreover, what is necessary is just to scrape off the front-end | tip of the convex part 1b of the prototype resin mold 1 when you want to make the protrusion height of the convex part 2a of the prototype building material 2 smaller. Adjustment of the depth of the recess 2b of the prototype building material 2 can be performed in the same manner.

  The prototype resin mold 1 is usually shaved by a removal process such as cutting or polishing to correct the shape. However, it is possible to modify the shape of the prototype resin mold 1 by preparing a reinforcing resin composed of components similar to the prototype resin mold 1 and fixing the reinforcing resin to the prototype resin mold 1. It is. In this case, there is a possibility that a step is generated at the interface between the reinforcing resin and the prototype resin mold 1 or a discontinuous boundary line is formed. However, in this embodiment, since the master mold 3 is produced, the electroforming mold A It is possible to prevent the reinforcing shape from being inherited.

  The modification of the shape of the prototype resin mold 1 may be a modification of the entire surface or a modification of a part of the surface. When a part of the surface is corrected, the shape can be corrected efficiently because the correction process may be performed partially. Further, in this embodiment, the transfer model 4 is formed from the master mold 3 instead of forming the transfer model 4 from the prototype resin mold 1. Therefore, when the master mold 3 is manufactured, some corrections are made on the entire surface. It can be reflected. In addition, as in the building board 10 of FIG. 3, if the surface uneven pattern of the building material is a shape in which a certain pattern is arranged, the shape of the entire building material surface after the correction is obtained by partial correction of the prototype resin mold 1 Can be predicted, and the shape can be corrected efficiently with less processing.

  The press molding by the prototype resin mold 1 and the shape correction can be repeatedly performed. Thereby, the shape of the prototype resin mold 1 can be corrected with higher accuracy, and the shape of the produced building material can be brought close to the target shape.

  When the shape of the prototype resin mold 1 is corrected, the pattern data (basic data) is corrected and new pattern data (corrected data) can be obtained. At this time, the pattern data (basic data) may be corrected first, and the trial resin mold 1 may be corrected based on the corrected pattern data (corrected data). Alternatively, the corrected pattern data (corrected data) may be obtained by measuring the shape of the modified prototype resin mold 1 and correcting the pattern data (basic data) based on the measured value. . If the pattern data is managed by an electronic arithmetic device such as a computer, it can be easily corrected.

  Next, as shown in FIG.1 (c), the master type | mold 3 is produced based on the prototype resin type | mold 1 by which the shape was corrected.

  Since the master mold 3 is not used for press molding, it can be formed using a molding material that is easy to process, such as resin or gypsum. Thereby, the master mold 3 can be easily manufactured. The master mold 3 can be formed using a material that is easy to mold. Since the master mold 3 is not used in the trial production, it is not necessary to consider the required performance in the press molding. Therefore, the master mold 3 can be made of a material optimized for workability. For this reason, it is possible to suppress the occurrence of processing burrs and processing marks during the production of the master mold 3, and it is possible to avoid or reduce the manual finishing process by hand. Further, since a resin excellent in processability can be used, the pattern portion can be formed finely.

  As the material of the master mold 3, polyurethane resin, epoxy resin, acrylic resin, gypsum and the like can be used.

  Further, since the master mold 3 is for transferring the unevenness to the transfer model 4, it is preferable to use a hard resin whose hardness is higher than that of the resin used for the prototype resin mold 1 when formed with a resin. . Since the master mold 3 is not used for press molding, press moldability is not required. The master mold 3 is a mold material for forming the transfer model 4, and it is important to transfer the uneven pattern more faithfully when producing the transfer model. Therefore, the master mold 3 is preferably made of a material that is not easily deformed, and a hard resin is preferable.

  The master mold 3 is produced by taking shape data (pattern data) of the surface irregularities of the prototype resin mold 1 into an electronic arithmetic device, molding a molding material such as resin or gypsum based on the data calculated by the electronic arithmetic device, and This can be done by processing. As the pattern data, data (corrected data) obtained by correcting the basic data for producing the prototype resin mold 1 can be used. The processing may be cutting, cutting, etching, or the like. At this time, the master mold 3 is not press-molded and has higher workability than the prototype resin mold 1, and therefore can be processed easily and accurately. The master mold 3 may be manufactured by the same method as the processed resin mold.

  The master mold 3 is preferably a full-surface master mold that reflects an uneven pattern on the entire surface (the entire surface of one building material). Thereby, the formwork which provides an uneven | corrugated pattern to the whole surface of a building material can be formed. If a prototype building material 2 is produced by modifying a part of the prototype resin mold 1 and evaluated, the master mold 3 is produced so that the modified part is reflected on the entire surface of the master mold 3. Can be. By reflecting a partial correction of the prototype resin mold 1 in its entirety, the entire master mold can be efficiently manufactured.

  When the master mold 3 is manufactured, it is preferable that the master mold 3 is manufactured by correcting the shape of the prototype resin mold 1 instead of the same shape as the prototype resin mold 1. By correcting the shape data (pattern data) of the prototype resin mold 1 and creating the master mold 3 based on the corrected data, the pattern of the building material at the time of production can be further adjusted, and the target shape Can be approached.

  As corrections, there are corrections (alignment correction) so as not to inherit the shape change at the time of correcting the shape of the prototype resin mold 1, and press molding with the prototype resin mold 1 and press molding with the electroforming mold A. There is correction (dimension correction) for correcting the dimensional difference of the uneven pattern formed on the molded product. Of these corrections, it is preferable to perform either correction, and it is more preferable to perform both corrections. Furthermore, correction (pattern change correction) may be performed when it is desired to correct a pattern, for example, when the target shape of a building material is changed or finely corrected.

  The adjustment correction is correction that prevents the prototype resin mold 1 after being processed (step, burr, wear, etc.) from being reflected in the pattern data. If the corrected data includes processed data, the corrected data can be corrected by deleting or changing the processed data portion. If the modified data does not include the processed data, the correction data may be corrected by using a part and all of the basic data that does not include the processed data.

  By the adjustment correction, the difference between the corrected portion of the prototype resin mold 1 and the uncorrected peripheral portion is not inherited by the electroformed mold A, and it is possible to avoid impairing the design of the building board. For example, when the prototype resin mold 1 is stepped by correction processing, the master mold 3 is manufactured so that the surface is smooth by taking the step. In addition, when the shaving or wear has occurred, the master mold 3 is manufactured so that the surface is smoothed by the shaving or wear. The adjustment correction may be to remove processing burrs and processing marks. Even if the shape of the prototype resin mold 1 is changed due to progress, if the master mold 3 is manufactured from the corrected pattern data by the correction, the shape of the electroformed mold A is further adjusted. Can be produced. Further, when forming the transfer model 4 from the prototype resin mold 1, it is necessary to remove processing burrs and traces from the prototype resin mold 1, but the master mold 3 newly creates a mold from pattern data. It is possible to omit or reduce the work of removing processing burrs and processing marks. Therefore, it is possible to obtain the master mold 3 for forming the transfer model 4 with high accuracy and efficiency.

  Then, since the master mold 3 is formed based on the data corrected by the correction, the surface of the master mold 3 is prepared, and the pattern wear due to the trial manufacture of the prototype resin mold 1 is not inherited by the electroforming mold A, It can avoid impairing the design of the building material.

  In the dimension correction, after making a prototype with the prototype resin mold 1 and determining the specifications, the pattern data is corrected by correcting the difference in press molding depth between the prototype resin mold 1 and the electroforming mold A for production. Is. When the master mold 3 is produced from the dimension-corrected pattern data, the surface unevenness of the master mold 3 having the dimension corrected is transferred to produce the electroformed mold A. Thereby, the pattern depth of the building material press-molded by the prototype resin mold 1 and the production electroforming mold A becomes more the same, and it is more avoided that the building material having an unexpected appearance is generated. can do.

  FIG. 2 is a diagram for explaining the difference in the amount of deformation of the building material due to the difference in the material of the mold material during press molding. The building material press-molded with the prototype resin mold 1 and the production mold (electroformed mold A) ) Explains the dimensional error with the building material press-molded. The mold receives stress from the building material when pressed against the building material and pressed. At this time, since the mold is formed of a hard material, it can be molded almost as it is. On the other hand, since the resin is slightly deformed in the resin mold, the uneven depth tends to be smaller than the target value. Here, as shown in FIG. 2, the projection width of the molding die is L1, and the target depth (pattern depth) of the concave portion of the building material (the prototype building material 2 and the building board 10) molded by the molding die is as follows. Let L2. And the depth (pattern depth) of the recessed part of the building material (prototype building material 2 and building board 10) actually shape | molded with a shaping | molding die is set to L3. Then, when molded with the electroforming mold A, L1 = L2 = L3 is substantially established, but in the case of the prototype resin mold 1, L1 = 0.8 to 0.9 × L2 = L3 may be obtained. Therefore, if the shape of the prototype resin mold 1 is changed to the shape of the master mold 3 as it is, the electroformed mold A reflects the shape of the master mold 3, so that when the building material is press-molded with the electroformed mold A, Dimensional error occurs when the prototype is molded. The dimensional correction is to correct a dimensional error between the prototype and the produced product thus generated.

  The dimension correction may correct the dimension based on the amount of deformation of the resin that occurs when the prototype resin mold 1 is press-molded. The deformation amount of the resin may be based on an empirical value, or may be based on a value of the deformation amount actually measured.

  The dimension correction can be performed, for example, by increasing the dimension in the thickness direction of the prototype resin mold 1. Specifically, the protrusion width of the protrusion 3b of the master mold 3 can be set to a range of 1.01 to 1.5 times the protrusion width of the protrusion 1b of the prototype resin mold 1. . Alternatively, the depth (thickness) of the recess 3a of the master mold 3 is set to a range of 1.01 to 1.5 times the depth (thickness) of the recess 1a of the prototype resin mold 1. it can.

  The pattern change correction is correction for correcting the shape data (pattern data) when the prototype resin mold 1 is used for the trial manufacture and the uneven pattern needs to be corrected. Even when a building material is prototyped with the prototype resin mold 1 and the shape is almost determined, it may be desired to correct the uneven pattern. At this time, if the change is not so large that the prototype resin mold 1 is processed and modified and the prototype is re-executed, or if the change is such that the shape can be assumed by changing the data, the prototype resin mold 1 can be corrected and the prototype building material Pattern data can be changed without prototyping 2. Thus, the master mold 3 can be efficiently produced without the labor of processing the prototype resin mold 1 and the labor of trial manufacture of the prototype building material 2. Moreover, you may correct | amend by adding and changing the pattern data which forms the fine uneven | corrugated pattern which is formed in the convex part 11 surface of the building board 10 by pattern change correction | amendment.

  In this way, the master mold 3 is formed based on the uneven pattern data obtained from the modified shape of the prototype resin mold 1. In the present embodiment, basic data that is shape data of the prototype resin mold 1, correction data in which the basic data is corrected, and correction data in which the correction data is corrected are defined as pattern data. A master mold 3 is formed.

  Next, as shown in FIG. 1D, a transfer model 4 is produced based on the shape of the master mold 3.

  The transfer model 4 serves as a base material for electroforming plating, and the master mold 3 has the irregularities reversed to give the surface an irregular pattern.

  The transfer model 4 can be formed of an appropriate material suitable for electroforming plating. Further, a material capable of transferring the uneven pattern of the master mold 3 is used. For example, the transfer model 4 can be formed of a resin. As the resin, polyurethane resin, polycarbonate resin, or the like can be used.

  The uneven pattern on the surface of the transfer model 4 has the same shape as the uneven pattern of the building material to be produced. The transfer model 4 does not need to be cut after the production, and a material suitable for faithfully transferring the surface pattern of the master mold 3 can be used. The transfer model 4 is produced, for example, by applying a fluid material for forming the transfer model 4 to the uneven surface of the master mold 3, curing the applied material, and separating the transfer model 4 from the master mold 3. This can be done by molding.

  Next, as shown in FIG. 1 (e), the surface of the transfer model 4 is electroformed to form an electroformed plating portion 5.

  Electroforming plating (electrocasting plating) is to produce a thick plating layer by depositing metal on the surface by an electrochemical reaction. In electroforming, for example, a metal thin film is formed on the surface of the transfer model 4 (preliminary process), and this metal thin film is used as an electrode to cause an electrochemical reaction in an electrolytic solution, thereby laminating a metal on the surface of the metal thin film ( (This step). The metal thin film can be formed by sputtering or the like. As the electroforming plating conditions, for example, a nickel sulfamate simple bath can be used.

  For example, nickel or copper can be used as the plating metal. These metals are excellent in plating properties and can provide a mold having excellent strength when the mold is formed.

  The thickness of the electroformed plating part 5 is preferably 3 mm or more. If the thickness of the electroformed plating part 5 is thin, the strength of the electroformed mold A may be weakened. The upper limit of the thickness of the electroformed plating part 5 is not particularly limited. However, if the thickness is too thick, it may take too much time for manufacturing, and thus, for example, the thickness may be 10 mm or less.

  Next, as shown in FIG. 1 (f), the electroformed plating part 5 is released from the transfer model 4. The electroformed plating portion 5 has a back surface (surface opposite to the transfer model 4 side) joined to the backup material 6 and supported by the base substrate 7.

  Release of the electroformed plating part 5 can be performed by peeling the electroformed plating part 5 from the transfer model 4. At this time, the electroformed plating part 5 can be peeled off without supporting material, but more preferably, after the backup material 6 is joined to the electroformed plating part 5, the electroformed plating part 5 using the backup material 6 as a supporting material. Is peeled off from the transfer model 4. By joining the backup material 6 and the electroformed plating part 5 before releasing, it is possible to suppress the electroformed plating part 5 from being damaged.

  As a material of the backup material 6, for example, an epoxy resin, an acrylic resin, a polyurethane resin, or the like can be used.

  The electroformed plating part 5 is joined to the base substrate 7 by a backup material 6. The base substrate 7 has a structure that supports the electroformed plating part 5 and is attached to the press 8. By having the base substrate 7, attachment to and removal from the press machine 8 is facilitated. The base substrate 7 may be a metal material or a resin material.

  Thus, an electroforming mold A is obtained in which the electroformed plating part 5 is backed up and joined to the surface of the base substrate 7 by the backup material 6. The electroformed mold A is composed of a base substrate 7, a backup material 6, and an electroformed plating part 5. Of course, the base substrate 7 may be absent, the backup material 6 may be absent, or other members such as a reinforcing material may be included.

  By attaching this electroformed mold A to the press 8, a building material having a desired uneven pattern can be manufactured (produced). And in the electroformed mold A manufactured as described above, it is possible to reduce the adverse effect of the mold correction at the prototype stage of the building material on the design of the product, and the difference in the material of the press mold Therefore, the difference in shape between the prototype and the product can be reduced.

A Electroforming mold 1 Prototype resin mold 2 Prototype building material 3 Master mold 4 Transfer model 5 Electroformed plating part 6 Backup material 7 Base material 8 Press machine 10 Building board

Claims (3)

Prototype building materials are produced by press molding building materials with prototype resin molds,
Modify the shape of the prototype resin mold based on the shape of the prototype building material,
Based on the prototype resin mold whose shape has been corrected, the shape of the prototype resin mold is corrected so as to approach the shape of the target building material, and a master mold is produced.
The correction is an adjustment correction or a dimension correction,
Create a transfer model based on the shape of the master mold,
By forming electroformed plating on the surface of the transfer model,
A method for producing an electroforming mold for building materials, wherein the electroforming plating part is released from the transfer model. The method for manufacturing an electroforming mold for building materials according to claim 1, wherein the correction is further a pattern change correction. The method for manufacturing an electroforming mold for building materials according to claim 1 or 2 , wherein the master mold is made of a resin having a hardness higher than that of the prototype resin mold.

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