JP6798319B2 - Resin molding equipment and resin molding method - Google Patents

Description

The present invention relates to a resin molding apparatus and a resin molding method.

Conventionally, there is known a method in which an ultraviolet curable resin is used to form a three-dimensional molded product, and cured layers cured in layers by ultraviolet rays are sequentially laminated to obtain a desired three-dimensional molded product (Patent Document 1). Further, Patent Document 1 discloses that when a branched portion that does not reach the lower end of a three-dimensional molded product is formed, a cured layer for a dummy is formed in advance continuously under the branched portion. It is said that an accurate three-dimensional molded product can be obtained.

However, in the method of obtaining the three-dimensional molded product disclosed in Patent Document 1, it is necessary to add a portion corresponding to the cured layer for the dummy from the design stage, and further, for the dummy after the three-dimensional molding. It is necessary to remove the cured product. Therefore, a hot melt type ink containing different resin materials having different melting points is ejected from an inkjet head to form a single layer of a desired three-dimensional molded product formed of a high melting point ink and a desired three-dimensional shape of a low melting point ink. A method of forming a single layer in a region other than a molded product and laminating the single layer to form a three-dimensional object is disclosed (Patent Document 2).

Then, in the method disclosed in Patent Document 2, the low melting point ink is melted and removed from the formed solid by heating at a temperature higher than the melting point of the low melting point ink and lower than the melting point of the high melting point ink. By doing so, a desired three-dimensional molded product formed of a high melting point ink can be obtained.

Japanese Unexamined Patent Publication No. 2-251419 Japanese Unexamined Patent Publication No. 9-12329

In both the methods for forming a three-dimensional molded product disclosed in Patent Document 1 and Patent Document 2, there are restrictions on the materials that can be applied. In Patent Document 1, a material that can be cured by an energy beam containing ultraviolet rays must be used. Patent Document 2 requires a resin material that can be ejected and supplied from an inkjet head as a hot melt type ink.

However, in recent years, in modeling of a three-dimensional molded product (hereinafter referred to as 3D modeling), not only modeling of a desired shape but also desired quality, for example, strength, heat resistance, chemical resistance, etc. can be obtained by 3D modeling. Is becoming more and more demanding. Therefore, the method for forming a three-dimensional molded product disclosed in Patent Document 1 and Patent Document 2 is applied to prototypes and products that require materials that cannot be cured by an energy beam or materials having an extremely low melting point. It was difficult to do. Furthermore, there was no disclosure regarding multicolor molding using a material that cannot be cured by an energy beam or a material having an extremely low melting point.

Therefore, we provide a resin mold by 3D molding, a resin molding apparatus and a resin molding method capable of multicolor molding using a plurality of types of all kinds of thermoplastic resins by injecting a product resin material into the resin mold.

The present invention has been made to solve at least a part of the above-mentioned problems, and can be realized as the following forms or application examples.

[Application Example 1] In the resin molding apparatus of this application example, a stage, a storage tank installed on the stage, an energy ray irradiation unit for irradiating energy rays, and a first material which is a synthetic resin are plasticized. A first injection portion to be ejected from the injection port and a second injection portion to be ejected from the injection port by plasticizing a second material which is a synthetic resin are provided at least, and the stage and the energy ray irradiation are provided. The storage tank includes a table that can be driven at least in the direction of gravity, and includes a driving means that enables the portion, the first injection portion, and the second injection portion to move relatively three-dimensionally. In preparation for the above, a liquid cured resin material containing an energy ray-curable resin that is cured by the energy rays is stored.

According to the resin molding apparatus of this application example, it is possible to inject at least two types of thermoplastic resin and an energy ray irradiation part that cures an energy ray curable resin that is easy to perform three-dimensional modeling, so-called 3D modeling, by energy ray irradiation. A mold capable of injection molding at least two types of thermoplastic resins can be formed by 3D molding in which an energy ray-curable resin is irradiated with an energy ray and cured by providing an injection portion capable of forming the mold. The lead time from design, mold making, mold manufacturing for mold assembly to injection molding of products can be set shorter than before. This makes it possible to mold a high-performance resin material that cannot be applied to an energy ray-curable resin in a short time and at a low cost by not producing an expensive mold.

[Application Example 2] In the above-mentioned application example, the energy rays emitted from the irradiation portion cure the cured resin material to form a layered first molded product, which is then ejected from the first injection portion. One or both of the first material and the second material ejected from the second injection portion are cured to form a second molded product in a layered manner, and the first molded product is formed. It is characterized in that a first molded body laminated in the direction of gravity and a second molded body in which the second molded product is laminated in the direction of gravity are formed.

According to the above-mentioned application example, it is possible to easily obtain a first molded body formed in 3D and a second molded body formed in 3D using two kinds of materials.

[Application Example 3] In the above-mentioned application example, the first molded product is formed with a cavity for forming the second molded product, and the second molded product is the first material and the second material. At least one or both of the above are ejected and filled into the cavity.

According to the above-mentioned application example, using the first molded body as a molding die, at least two kinds of materials, a first material and a second material, are injection-molded in the cavity formed in the first molded body. The lead time from mold design, mold manufacturing, mold assembly to mold injection molding of products can be set shorter than before. This makes it possible to mold a high-performance resin material that cannot be applied to an energy ray-curable resin in a short time and at a low cost by not producing an expensive mold.

[Application Example 4] The above-mentioned application example is characterized in that the energy ray is ultraviolet rays.

According to the above-mentioned application example, since it is a low calorific value energy ray having high productivity due to a short curing time and a small calorific value of the irradiated portion and ultraviolet rays, the thermal effect on the second material constituting the second molded product. Can be avoided.

[Application Example 5] In the above-mentioned application example, the synthetic resin is a thermoplastic resin.

According to the above-mentioned application example, precise molding by injection molding becomes possible.

[Application Example 6] In the resin molding method of this application example, a liquid cured resin material containing an energy ray-curable resin stored in a storage tank installed on a stage is irradiated with energy rays, and the energy ray-curable resin is irradiated. Molded product single layer forming step of forming a single layer of a single-layer molded product by curing, and a first material which is a plasticized synthetic resin is injected from a first injection portion to form the molded product. A first single-layer injection molding step of filling and solidifying a first cavity region constituting a single-layer cavity to form a molded single layer, and a second material which is a plasticized synthetic resin. Is injected from the second injection portion, and the second cavity region constituting the cavity of the molded product single layer is filled and solidified to form the molded product single layer. And, the first mold molded product single layer formed by the mold molded product single layer forming step is laminated, and the second mold molded product single layer is formed by the mold molded product single layer forming step. The first single-layer injection molding step, the first single-layer injection molding step, and the first single-layer injection molding step of laminating the first molded product single layer formed by the step, the first single-layer injection molding step, and the second single-layer injection molding step. The second single-layer injection molding step and the molded product laminating step of forming the second molded product single layer by the second single-layer injection molding step are repeated, and the mold molding laminating step is repeated a predetermined number of times. A molded body in which a predetermined number of layers are laminated and a molded body in which the molded product laminating step is repeated a predetermined number of times to form a molded body laminated and filled in the cavity of the molded product. It is characterized by.

According to the resin molding method of this application example, at least two types of thermoplastic resins are applied to a mold molded product obtained by curing an energy ray-curable resin that is easy to mold in 3D by energy beam irradiation and laminating. A molded body can be obtained by injection and laminating, and the lead time from mold design, mold manufacturing, mold assembly to mold manufacturing to product injection molding can be set shorter than before. Therefore, it enables a resin molding method capable of reducing the cost of a high-performance resin material that cannot be applied to an energy ray-curable resin in a short time and by not producing an expensive mold.

[Application Example 7] In the above-mentioned application example, in the mold molding single layer forming step, the cured resin material is cured at the boundary between the first cavity region and the second cavity region. It is characterized by including a boundary wall layer forming step of forming the boundary wall to be formed.

According to the above-mentioned application example, the boundary between the first cavity region and the second cavity region can be determined by forming the boundary wall. Therefore, the material injected into the first cavity region and the material injected into the second cavity region are precisely injection molded into the first cavity region and the second cavity region.

Further, even if the material injected into the first cavity region and the material injected into the second cavity region do not have high affinity or adhesion, the boundary wall is the first cavity. A material injected into the tee region, a material injected into the second cavity region, a material injected into the first cavity region as an adhesive wall (adhesive layer), and a second cavity. It is possible to enhance the affinity or adhesion with the material injected into the region.

[Application Example 8] In the above-mentioned application example, a mold release step of releasing the molded product from the mold molded product is included, and the mold release step dissolves the mold molded product.

According to the above-mentioned application example, the molded product can be released from the molded product and obtained without damaging the molded product.

[Application Example 9] The above-mentioned application example is characterized in that the energy ray is ultraviolet rays.

According to the above-mentioned application example, the high productivity due to the short curing time and the low calorific value energy ray with a small amount of heat generated by the irradiated portion and the ultraviolet rays can avoid the thermal influence on the molded body.

[Application Example 10] In the above-mentioned application example, the synthetic resin is a thermoplastic resin.

According to the above-mentioned application example, precise molding by injection molding becomes possible.

The block diagram which shows the schematic structure of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the driving of the resin molding apparatus which concerns on 1st Embodiment. The flowchart of the resin molding method which concerns on 2nd Embodiment. FIG. 3 is an external perspective view showing a second molded body exemplified in the resin molding method according to the second embodiment. The detailed flowchart of the mold molding single layer forming process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The detailed flowchart of the single-layer injection molding process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. FIG. 19 is an enlarged view of part A shown in FIG. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. FIG. 25 is an enlarged view of part B shown in FIG. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. FIG. 27 is an enlarged view of part C shown in FIG. 27. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. FIG. 3 is an external perspective view showing a second molded body exemplified in the resin molding method according to the third embodiment. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 3rd Embodiment. FIG. 31 is an enlarged view of part D shown in FIG. The schematic cross-sectional view which shows the manufacturing process of the resin molding method which concerns on 3rd Embodiment.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.

(First Embodiment)
FIG. 1 is a configuration diagram showing a schematic configuration of a resin molding apparatus according to the first embodiment. The resin molding apparatus 1000 shown in FIG. 1 is a liquid cured resin material as a second liquid material containing an energy ray-curable resin which is installed in a stage 200 and a stage 200 and is cured by being irradiated with energy rays inside. A storage tank 300 in which a storage space 300a for storing the liquid resin material Mf is formed, and a base 100 provided with a stage driving device as a driving means (not shown) for driving the stage 200 three-dimensionally. The three-dimensional drive is such that it can be driven in any of the X, Y, and Z directions shown in the figure.

In the storage space 300a of the storage tank 300, a molding unit 400 including a table 410 having a molded product forming surface 410a (hereinafter referred to as a forming surface 410a) and a drive shaft 420 for driving the table 410 in the Z-axis direction is provided. Have been placed.

As described above, in the resin molding apparatus 1000, the liquid resin material Mf containing the energy ray-curable resin as the second material is stored in the storage tank 300, and the liquid resin material Mf is stored on the forming surface 410a by the energy rays as described later. Since it is an apparatus for curing, forming a cured layer, and laminating, the liquid upper surface of the liquid resin material Mf and the forming surface 410a are arranged substantially in parallel. Therefore, it can be said that the Z-axis direction shown is the so-called gravity direction, and the table 410 is driven in the gravity direction.

An energy ray irradiation unit 500 that irradiates energy rays toward the liquid upper surface of the liquid resin material Mf is arranged above the storage tank 300 in the direction of gravity. In the resin molding apparatus 1000 according to the present embodiment, ultraviolet rays will be illustrated and described as energy rays. Therefore, the energy ray irradiation unit 500 will be described below as the ultraviolet irradiation unit 500. The energy rays are not limited to ultraviolet rays, and may be high frequencies, radiation, or other energy rays and energy ray-curable resins that impart energy for curing the irradiated object.

Further, in the upper part of the storage tank 300 in the direction of gravity, a first injection portion 610 (hereinafter, hereinafter, injection portion 610) which plasticizes and injects a resin material Mp1 as a first material which is a synthetic resin which is a material constituting a part of a product A second injection part 620 (hereinafter referred to as a second injection part 620) that plasticizes and injects a first injection part (referred to as) and a resin material Mp2 as a second material which is a synthetic resin which is a material constituting another part of the product. (It is called an injection unit 620) and is arranged. In the present embodiment, injection portions 610 and 620 including a flat screw will be described as an example.

Since the first injection unit 610 and the second injection unit 620 exemplify the same device configuration, the configuration of the first injection unit 610 will be described. The first injection unit 610 includes a heater (heating means) (not shown), and is a driving device that rotationally drives a cylinder 612 having an internal space, a flat screw 613 arranged in the internal space of the cylinder 612, and at least the flat screw 613. It includes a 614 and a material supply unit 611 that supplies a pellet-shaped resin material Mp1 to the internal space of the cylinder 612.

The pellet-shaped resin material Mp1 supplied to the cylinder 612 is heated to a temperature equal to or higher than the glass transition point by a heater provided in the cylinder 612 to become a plasticized resin material Mp1. The plasticized resin material Mp1 is delivered to the injection port 612b by rotating the flat screw 613, and is ejected from the injection port 612b.

The principle of injection of the resin material Mp1 by the flat screw 613 is that the pellet-shaped resin material Mp1 is conveyed from the material supply unit 611 to the material input port 612a of the cylinder 612 and plasticized by the heater of the cylinder 612. The plasticized resin material Mp1 was formed in a spiral shape from the outside of the flat screw 613 toward the rotation center 613r by rotating the flat screw 613 around the rotation center 613r by the drive device 614. The resin material Mp plasticized along the transport groove 613a is pressure-conveyed toward the rotation center 613r, and is ejected from the injection port 612b by the pressure.

In the resin molding apparatus 1000 according to the present embodiment, the second injection unit 620 also includes the same components as the first injection unit 610, and includes a material supply unit 621, a cylinder 622, a flat screw 623, and a drive device 624. ing. Then, the resin material Mp2 is injected from the injection port 622b. The first injection unit 610 and the second injection unit 620 are not limited to having the same configuration. At least, it is sufficient that different resin materials Mp1 and Mp2 can be injected.

As described above, it is preferable to use a thermoplastic resin for the resin material Mp1 injected from the first injection unit 610 and the resin material Mp2 injected from the second injection unit 620. Further, different resin materials can be used for Mp1 and Mp2. Different resin materials are referred to as different resin materials if they are not exactly the same, such as when the resin compositions are different, or when the same composition has different physical properties such as color tone, hardness, and glass transition point.

The resin molding apparatus 1000 according to the present embodiment includes a control unit 700, a stage controller 710 that controls the drive of a stage drive device (not shown) provided in the base 100, and molding that is driven in the direction of gravity in the storage tank 300. Injection that controls a table controller 720 that controls a table driving device (not shown) that drives the unit 400, an ultraviolet irradiation control unit 730 that controls the ultraviolet irradiation unit 500, a first injection unit 610, and a second injection unit 620. Control unit 740 and.

2 to 5 are views for explaining the driving of the resin molding apparatus 1000. FIG. 2 is a schematic configuration diagram showing a preparatory stage for resin molding by the resin molding apparatus 1000. As shown in FIG. 2, in the preparatory stage of resin molding of the resin molding apparatus 1000, the liquid resin material Mf in which a cured product is produced by irradiating the storage space 300a of the storage tank 300 with ultraviolet UV as energy rays is provided. Store.

Then, the forming surface 410a of the table 410 is submerged at a depth D _L1 from the liquid surface Sf of the stored liquid resin material Mf. The depth D _L1 is the amount of subduction of the table 410 required to obtain the thickness of the first layer of the molded product described later.

In the first injection section 610 and the second injection section 620, pellet-shaped resin materials Mp1 and Mp2 are charged from the hoppers 611a and 621a of the material supply section 611 and 621 and conveyed to the cylinders 612 and 622. In the cylinders 612 and 622, the resin materials Mp1 and Mp2 are heated to a temperature exceeding the glass transition point and plasticized by a heater (not shown). Then, the resin materials Mp1 and Mp2 plasticized by the rotation of the flat screws 613 and 623 are pressurized and conveyed to the injection ports 612b and 622b.

When the preparation for resin molding of the resin molding apparatus 1000 shown in FIG. 2 is completed, as shown in FIG. 3, ultraviolet UV rays as energy rays are emitted from the ultraviolet irradiation port of the ultraviolet irradiation unit 500 toward the liquid level Sf of the liquid resin material Mf. Is irradiated. Then, in synchronization with the irradiation of the ultraviolet UV, the stage 200 is driven in the XY directions relative to the ultraviolet irradiation unit 500 by a stage driving device (not shown) provided in the base 100, and the storage tank arranged in the stage 200. The 300 is moved in the XY directions relative to the ultraviolet irradiation unit 500. Then, the liquid resin material Mf is cured by ultraviolet UV is irradiated, the first mold layer 810 in the first layer having a thickness of D _L1 is formed on the forming surface 410a.

The resin material Mp1 plasticized from the injection port 612b of the first injection portion 610 is injected into a predetermined injection region as shown in FIG. 4 in the molding region 810s surrounded by the first molding layer 810 described with reference to FIG. Then, the first molded layer 911 as the second molded product of the first layer made of the resin material Mp1 is formed on the forming surface 410a. In this example, the resin material Mp1 is injected from the first injection portion 610 to form the first molding layer 911, with the inside of the first molding layer 810 formed in a frame shape as the first molding region 810s. Although the form is illustrated, the resin material Mp2 may be injected from the second injection portion 620 into the molding region 810s to form the first molding layer. Since the first molding layer 911 is a single layer of the resin material Mp1 in this example, the first molding layer 911 will be described below as the first molding layer 910.

As described above, in the resin molding apparatus 1000 according to the present embodiment, the liquid resin material Mf is cured by ultraviolet UV to form the first mold layer 810, and the first mold layer 810 is plasticized as a mold. The resin material Mp1 is injected from the injection section 610 to form the first molded layer 910 to form a layered molded product. Then, the layered molded product is repeatedly formed and laminated to form the molded product on the forming surface 410a of the table 410.

5 and 6 show a form in which a second molding mold layer 820 for forming a second molding layer laminated on the first molding layer 910, which will be described later, is formed. The formation of the second mold layer 820 is based on the formation of the connection layer 820a shown in FIG. 5 and the formation of the upper layer 820b shown in FIG.

The connection layer 820a constituting the second mold layer 820 shown in FIG. 5 is formed. So that the depth of the depth D _L2A corresponding to the thickness of the connection layer 820a, the forming surface 410a of the table 410 so that the upper surface 810f of the first mold layer 810 sinking from the liquid surface of the liquid resin material Mf Move.

As shown in the drawing, the connection layer 820a has a frame-shaped first connection layer 821a and a frame-shaped second connection arranged inside the first connection layer 821a in an arrow view along the Z axis from above the drawing. A layer 822a and a third connection layer 823a arranged between the first connection layer 821a and the second connection layer 822a are formed. An upper layer 820b is formed on the formed connection layer 820a.

As shown in FIG. 6, so that the depth of the depth D _L2B corresponding to the thickness of the upper layer 820b, formed in the table 410 so that the upper surface 82Af connection layer 820a sinking from the liquid surface of the liquid resin material Mf The surface 410a is moved. Then, by irradiating the liquid resin material Mf from the ultraviolet irradiation unit 500 with ultraviolet UV and moving the storage tank 300 arranged on the stage 200 in the relative XY directions, the upper layer having a thickness of _DL2B is formed. The 820b is formed on the connecting layer 820a having the thickness of D _L2A , and the second molding mold layer 820 as the first molded product of the second layer having the thickness of D _L2 is formed.

As shown in the drawing, the upper layer 820b has a first upper layer 821b formed so as to overlap the first connecting layer 821a and a second upper layer so as to overlap the second connecting layer 822a when viewed from above the drawing along the Z axis. 822b is formed. In this example, a mode in which an upper layer is not formed on the third connection layer 823a will be described.

The connection layer 820a and the upper layer 820b are laminated to form the second mold layer 820. Between the laminated body of the first connecting layer 821a and the first upper layer 821b formed in a frame shape, and the laminated body of the second connecting layer 822a and the second upper layer 822b formed in a frame shape. The molding region 820s of the second layer molded body is formed by. The molding region 820s includes a first molding region 82As and a second molding region 82Bs whose boundary is substantially the forming portion of the third connecting layer 823a.

As shown in FIG. 7, the first injection portion 610 to the first material for the molding region 820s formed in the second molding mold layer 820 as the first molded product of the second layer shown in FIG. The resin material Mp1 is injected. The injected resin material Mp1 is controlled to an amount that can fill the first molding region 82As, and the first molding layer 921 is formed as the molding layer of the resin material Mp1 in the second molding layer 920 of the second layer. ..

At this time, the third connecting layer 823a arranged in the molding region 820s is prevented from protruding into the second molding region 82Bs beyond the first molding region 82As, which is the molding region of the resin material Mp1. Further, the first molding layer 921 is prevented from protruding into the second molding region 82Bs beyond the first molding region 82As, which is the molding region of the resin material Mp1, so that the first molding layer 921 is formed on the inner peripheral surface of the second molding layer 820. The transferability to the shape can be enhanced.

Subsequently, as shown in FIG. 8, the injection port 622b of the second injection portion 620 is relatively moved to a position corresponding to the second molding region 82Bs in which the resin material is not filled, and the resin material Mp2 is injected. .. The amount of the injected resin material Mp2 is controlled so that the second molding region 82Bs can be filled, and the second molding layer 922 is formed as the molding layer of the resin material Mp2 in the second molding layer 920. .. At this time, the second molding region 82Bs is formed by the third connecting layer 823a arranged in the molding region 820s and the first molding layer 921 on which the resin material Mp1 is formed, and the second molding layer 922 is formed. It is possible to improve the transferability of the second molding layer 820 to the inner peripheral surface shape.

As described above, in the molding region 820s of the second molding mold layer 820, two layers are formed by the first molding layer 921 formed of the resin material Mp1 and the second molding layer 922 formed of the resin material Mp2. The second molding layer 920 of the eye is laminated on the first molding layer 910.

Then, as shown in FIG. 9, the formed second mold layer 820 and the second mold layer 920 are laminated with the third mold layer 830 and the third mold layer 930. Further, the lamination is repeated, and the Nth molding layer 8N0 and the Nth molding layer 9N0 are laminated as the uppermost layer, and the molding region formed by the first molded body 800 and the first molded body 800. The so-called cavity is filled with the resin material Mp1 and the resin material Mp2 to form the second molded product 900.

In this example, the second molded body 900 can be said to be a so-called two-color molded product in which the resin material Mp1 and the resin material Mp2 are integrally molded. The resin molding apparatus 1000 according to the present embodiment has been described as having two injection parts, a first injection part 610 and a second injection part 620, but the present invention is not limited to this, and three or more injection parts are provided. It may be a resin molding apparatus including an injection portion. Further, although it is preferable to use different materials for the resin material Mp1 and the resin material Mp2, the same resin material can also be used.

As described above, the first molded body 800 is a molding resin mold in which a cavity, which is a space for molding the second molded body 900, is formed. Therefore, it is not necessary to prepare an expensive metal mold, that is, a mold for manufacturing the second molded product 900, which is a product, and the liquid resin material Mf can be easily cured by ultraviolet UV as an energy ray. It enables three-dimensional modeling, so-called 3D modeling. Further, the second molded body 900 to be a product is formed by so-called injection molding in which the resin materials Mp1 and Mp2 of the thermoplastic resin are injected from the injection portions 610 and 620 and the first molded body 800 is molded as a molding die. Can be done. Therefore, the resin materials Mp1 and Mp2 may be thermoplastic resins. This means that, conventionally, in a modeling apparatus that generally performs 3D modeling with an ultraviolet curable resin, the resin material of the product is limited to the ultraviolet curable resin. In other words, if a resin that cannot be cured by ultraviolet rays is designated as a product resin, it has to rely on injection molding using a mold.

According to the resin molding apparatus 1000 according to the present embodiment, a mold for injection molding of a thermoplastic resin can be molded with an energy ray-curable resin capable of 3D molding in a short time and at low cost. Therefore, it is possible to mold a high-performance resin material that cannot be applied to an energy ray-curable resin in a short time and at a low cost by not producing an expensive mold.

Further, the resin molding apparatus 1000 according to the present embodiment may be a so-called two-color molded second molded body 900 that is compositely molded by a plurality of resin materials, in this example, two types of resin materials Mp1 and Mp2. It is possible to mold a high-performance resin material that cannot be applied to an energy ray-curable resin in a short time and at a low cost by not producing an expensive mold.

Examples of the ultraviolet curable resin include acrylate radical polymerization and epoxy cationic polymerization, but it can be said that resins other than this resin material are not suitable for molding by ultraviolet curing. Examples of the thermoplastic resin material applicable to the second molded product 900 include Pe (polyethylene), PP (polypropylene), PA (polypropylene), POM (polyacetylene), and PBT (polybutylene terephthalate) as crystalline resins. ), PPS (polyphenylene terephide), PEEK (polyetheretherketone) and the like. Further, as the liquid crystal resin, LCP (liquid crystal polymer (Liquid Crystal Polymer)) can be mentioned. Examples of the amorphous resin include PS (polystyrene), ABS, PMMA (acrylic), PC (polycarbonate), PPE (polyphenylene ether) and the like.

In the resin molding device 1000 described above, the ultraviolet irradiation unit 500 and the injection units 610 and 620 can move relatively three-dimensionally with respect to the molding unit 400 by a stage drive device (not shown) of the stage 200 provided on the base 100. Although it was a device, it is not limited to this. For example, the device may be a device in which the ultraviolet irradiation unit 500 and the injection units 610 and 620 are held by the robot arm and driven three-dimensionally relative to the molding unit 400.

(Second Embodiment)
As the second embodiment, one embodiment of the resin molding method using the resin molding apparatus 1000 according to the first embodiment will be described. FIG. 10 is a flowchart of the resin molding method according to the second embodiment. In the flowchart shown in FIG. 10, a predetermined amount of the liquid resin material Mf is stored in the storage tank 300 provided in the resin molding apparatus 1000 in advance as a preparation for manufacturing, and the pellet-shaped resin is stored in the material supply unit 611 of the first injection unit 610. The material Mp1 is supplied, and the pellet-shaped resin material Mp2 is supplied to the material supply unit 621 of the second injection unit 620. Then, the resin materials Mp1 and Mp2 heated and plasticized by a heater (not shown) provided in the cylinders 612 and 622 are conveyed to the injection ports 612b and 622b. This manufacturing preparation is completed, and the flowchart shown in FIG. 10 is started.

In the description of the resin molding method according to the second embodiment, the molding method will be described by taking the form shown in the external perspective view of FIG. 11 as an example of the second molded body 900 described in the first embodiment. Hereinafter, the second molded body 900 is referred to as a molded body 900. As shown in FIG. 11, the molded body 900 includes a first molded body 901 having a cross-sectional shape of a first cross section 901a molded by a resin material Mp1 as a first material, and a resin as a second material. An example is an example of a container having an outer shape of a conical base having a second molded body 902 having a cross-sectional shape of a second cross section 902a molded from the material Mp2 and a cross-sectional shape 900a having an internal space and a bottom formed of the second molded body 902.

(Molded product single layer forming process)
First, the mold molding single layer forming step (S1) is executed. A detailed flowchart of the mold molding single layer forming step (S1) is shown in FIG.

(Drive the stage table to the molding start position)
In the preparation step described above, the storage tank 300 in which the liquid resin material Mf is stored and the table 410 provided in the storage tank 300 are driven by the stage drive device provided in the base 100, and the table is driven to the molding start position ( The step S11) is executed. In the step of driving the table to the molding start position (S11), as shown in FIG. 13, the interval Duv between the forming surface 410a of the table 410 and the ultraviolet emitting portion 500a of the ultraviolet irradiation unit 500 is set to a predetermined interval. The relative positions of the table 410 and the ultraviolet irradiation unit 500 are set. The predetermined interval of the interval Duv is a distance that the energy that the ultraviolet UV emitted from the ultraviolet irradiation unit 500 can cure the liquid resin material Mf directly above the forming surface 410a can be reached. Then, the table 410 and the storage tank 300 are moved so that the relative positions of the table 410 and the storage tank 300 are such that the forming surface 410a is at a position where the depth D _L1A is located from the liquid level Sf of the liquid resin material Mf. The depth D _L1A is the molding thickness of the first connecting layer to be connected and formed on the forming surface 410a described later, which should be formed first.

(Ultraviolet irradiation process)
When the ultraviolet irradiation unit 500 is arranged at a predetermined relative position with respect to the table 410, the ultraviolet irradiation step (S12) is executed. The ultraviolet irradiation step (S12) includes a connection layer forming step (S121), an upper layer forming step (S122), and an upper layer stacking number confirmation step (S123). In the resin molding method according to the present embodiment, a plurality of single layers are laminated to form one molding mold layer. Therefore, in the ultraviolet irradiation step (S12), the connection layer forming step (S121) is first executed. As shown in FIG. 14, the stage 200 is driven so that the ultraviolet irradiation unit 500 moves relative to the table 410 while maintaining the depth D _L1A and irradiating the ultraviolet UV from the ultraviolet irradiation unit 500. By relatively moving the ultraviolet irradiation unit 500 along the outer shape of the molded body 900 shown in FIG. 11 while irradiating the ultraviolet UV, the first molding layer 810 as a single layer of the first molding is formed. The connecting layer 810a is formed.

When the connection layer 810a is formed, the process proceeds to the upper layer forming step (S122). In the upper layer forming step (S122), a table 410 as shown in FIG. 15, the relative positions of the reservoir 300, the upper surface of the connection layer 810a becomes the depth D _L1B from the liquid surface Sf of the liquid resin material Mf position The table 410 and the storage tank 300 are moved so as to be. The depth D _{L1 B} is the thickness of the upper layer laminated on the connection layer 810a.

Then, as shown in FIG. 16, the liquid resin material Mf is cured by ultraviolet UV irradiation from the ultraviolet irradiation unit 500 on the connection layer 810a to form the upper layer 810b. When the upper layer 810b is formed by the upper layer forming step (S122), the process proceeds to the upper layer stacking number confirmation step (S123). In this example, the form of the two-layer structure of the connection layer 810a and the upper layer 810b is illustrated. Therefore, the number of upper layers stacked is one, which is the same as the number of upper layers of the formation control data read into the control unit 700 (see FIG. 1) in advance (YES). Therefore, the ultraviolet irradiation step (S12) is completed, and the process proceeds to the next single-layer injection molding step (S2).

In the upper layer stacking number confirmation step (S123), when the number of upper layers stacked is less than the number of upper layers stacked in the formation control data (NO), the process proceeds to the upper layer forming step (S122) again, and the upper layer is added to the previously formed upper layer. When the layers are laminated and the number of layers of the upper layer reaches the number of layers of the upper layer of the formation control data (YES), the ultraviolet irradiation step (S12) is terminated, and the process proceeds to the next single-layer injection molding step (S2). In the resin molding method according to the present embodiment exemplified above, the number of upper layers laminated is set to one, but the number of layers is not limited to this, and a plurality of layers may be laminated. Further, the ultraviolet irradiation step (S12) may be completed when the number of upper layers laminated is 0, that is, one layer of the connecting layer 810a.

(Single layer injection molding process)
In the single-layer injection molding step (S2), the first molding mold layer 810 as the first molding molding single layer formed by the ultraviolet irradiation step (S12) is formed on the forming surface 410a of the table 410 as a mold. A single layer as a part of the molded body 900 is injection-molded in the molding region 810s to be molded. FIG. 17 shows a detailed flowchart of the single-layer injection molding step (S2).

(First injection molding process execution necessity confirmation process)
The resin molding method according to the present embodiment is a resin molding method using the resin molding apparatus 1000 according to the first embodiment, and as shown in FIG. 1, the first injection portion 610 and the second injection portion 620 Since it is provided with two injection portions, in the single-layer injection molding step (S2), first, the first injection molding for confirming whether or not the first injection molding step as the first single-layer injection molding step needs to be executed is confirmed. The process execution necessity confirmation step (S21) is executed. In the first injection molding step execution necessity confirmation step (S21), the necessity of driving the first injection unit 610 is determined from the formation control data read in advance in the control unit 700 (see FIG. 1).

In the first injection molding step execution necessity confirmation step (S21), the molding region 810s of the first layer is not the injection region of the resin material Mp1 as the first material injected from the first injection portion 610 (NO). If it is determined, the injection molding by the first injection unit 610 is not executed, and the second injection molding step for confirming whether or not the second injection molding step as the second single-layer injection molding step described later needs to be executed is performed. The process proceeds to the execution necessity confirmation step (S24).

In the resin molding method according to the present embodiment, the molding region 810s is exemplified as a region for filling the resin material Mp1. Therefore, in the first injection molding step execution necessity confirmation step (S21), from the first injection portion 610. It is determined that the injection of the resin material Mp1 is executed (YES), and the table 410 is driven to the injection molding start position.

(Drive the table to the injection molding start position by the first injection part)
As shown in FIG. 18, the injection molding start position of the first injection portion for driving the stage 200 so that the injection port 612b of the first injection portion 610 is arranged at the injection start position as a relative position with respect to the table 410. Drive (S22) is executed. At this time, the stage 200 is driven without changing the depth D _L1 of the liquid resin material Mf on the forming surface 410a of the table 410 from the liquid level Sf.

(First injection molding process)
When the step of driving the table to the injection molding start position by the first injection part (S22) is executed, it is conveyed to the injection port 612b of the first injection part 610 in the preparation step, and is conveyed by the heater provided in the first injection part 610. As shown in FIG. 19, the resin material Mp1 heated and plasticized above the glass transition point of the resin material Mp1 is injected from the injection port 612b toward the table 410 by a predetermined pressure. At this time, the resin material Mp1 is injected and filled into the molding region 810s which is a cavity formed inside the first molding mold layer 810 formed in the mold molding single layer forming step (S1). The first injection molding step (S23) as the layer injection molding step is executed.

The state of injection of the resin material Mp1 from the injection port 612b of the first injection unit 610 shown in FIG. 19 will be described with reference to FIG. 20 of an enlarged view of part A. For convenience of explanation in FIG. 20, the plasticized resin material Mp1 is referred to as a plastic resin Mpf, and the resin material Mp1 solidified from the plasticized state is referred to as a solidified resin Mps.

As shown in FIG. 20, the plastic resin Mpf is pressurized by the rotational drive of the flat screw 613 and is ejected from the injection port 612b. The injected plastic resin Mpf cools below the glass transition point in the process of reaching the forming surface 410a of the table 410, so that the form changes to the solidified resin Mps. The plastic resin Mpf is continuously laminated and solidified on the solidified solidified resin Mps, and the solidified resin Mps is formed as a molded product in the molding region 810s of the first molding mold layer 810.

At this time, the uncured liquid resin material Mf remains inside the first molding layer 810 formed in a frame shape, that is, in the molding region 810s, so that the plastic resin Mpf remains the liquid resin. It can be cooled by touching the material Mf to promote solidification into a solidified resin Mps. Therefore, it is possible to shorten the time of the plastic resin Mpf state on the forming surface 410a, prevent unnecessary flow in the XY directions shown in the figure, so-called outflow, and perform molding with an accurate shape. it can.

As described above, the first injection unit 610 provided in the resin molding apparatus 1000 according to the first embodiment used in the resin molding method according to the present embodiment applies pressure from the injection port 612b to inject the plastic resin Mpf. It is a method, which is one embodiment of a so-called injection molding method. The second injection unit 620, which will be described later, is also an embodiment of an injection molding method in which pressure is applied from the injection port 622b to inject the plastic resin Mpf.

Then, as shown in FIG. 21, the stage 200 is driven so that the first injection unit 610 moves a predetermined path facing the table 410 while injecting the plasticized resin material Mp1 from the injection port 612b. The resin material Mp1 is arranged in the molding region 810s formed by the first molding layer 810, and the first molding layer 910 as the first molding single layer of the first layer is formed and the first injection molding step. (S23) ends. Since the present embodiment illustrates the formation of the molded body 900 shown in FIG. 11, the first molded layer 910 corresponds to the bottom of the molded body 900 and is formed in a flat plate shape.

(Second injection molding process execution necessity confirmation process)
When the first injection molding step (S23) is completed, a second injection molding step execution necessity confirmation step (S24) for confirming the necessity of executing the second injection molding step as the second single-layer injection molding step is completed. ). The second injection molding step execution necessity confirmation step (S24) is the same as the first injection molding step execution necessity confirmation step (S21) described above, and the resin as the second material from the second injection part 620. The necessity of driving the second injection unit 620 is determined from the formation control data read in advance in the control unit 700 (see FIG. 1) to determine whether or not the material Mp2 is driven.

In the second injection molding step execution necessity confirmation step (S24), the molding region 810s of the first layer is not the injection region of the resin material Mp2 as the second material injected from the second injection portion 620 (NO). If it is determined, the injection molding by the second injection unit 620 is not executed, the single-layer injection molding step (S2) is completed, and the process proceeds to the step (S3).

Further, in the second injection molding step execution necessity confirmation step (S24), the molding region 810s of the first layer is an injection region of the resin material Mp2 as the second material injected from the second injection portion 620 ((S24). If YES) is determined, the table is driven to the injection molding start position by the second injection portion (S25), and each step of the second injection molding step (S26) as the second single-layer injection molding step is executed. Will be done. However, in the resin manufacturing method according to the present embodiment, since the first molding layer 910 is formed by the resin material Mp1 as the first material, the second injection molding step execution necessity confirmation step (S24). Is determined to be NO, the single-layer injection molding step (S2) is completed, and the process proceeds to the stacking number confirmation step (S3).

(Layered number confirmation process)
In the resin molding method according to the present embodiment, the molded body 900 is formed by laminating the single layers of the first molding mold layer 810 and the first molding layer 910 described above up to N layers (N: 1 or more natural numbers). .. Therefore, in the single-layer injection molding step (S2) immediately before the stacking number confirmation step (S3), the stacking number confirmation step (S3) for determining whether the N layers have been laminated is executed.

In the stacking number confirmation step (S3), when the number of laminated molded single layers is smaller than N (NO) by the immediately preceding single-layer injection molding step (S2), the process proceeds to the stacking step (S4).

(Laminating process)
The laminating step (S4) in the resin molding method according to the present embodiment is a command step for executing the repetitive molded product single-layer forming step (S1) and the single-layer injection molding step (S2), and confirms the number of laminated parts. A mold molding stacking step (S41) for instructing the repetition of the mold molding single layer forming step (S1) for forming a new mold molding single layer on the uppermost mold molding single layer confirmed in the step (S3). ) And the single-layer injection molding step (S2) for forming a new single-layer of the molded product on the single-layer of the uppermost molded product confirmed in the number-of-stacking confirmation step (S3). S42) and is included. According to the command issued by the mold molding laminating step (S41) included in the laminating step (S4), a new mold molding single layer is formed on the uppermost mold molding single layer already formed on the table 410. The process proceeds to the single-layer forming step (S1) of the molded product.

(Drive the table to the molding start position)
In the mold molded product single layer forming step (S1) executed based on the command of the mold molded product laminating step (S41) included in the laminating step (S4), first, the step of driving the table to the molding start position (S11) is executed. Will be done. As shown in FIG. 22, in the step of driving the table to the molding start position (S11), the upper surface of the first mold layer 810 as the first mold molded single layer formed on the table 410 and the ultraviolet irradiation unit. The relative positions of the table 410 and the ultraviolet irradiation unit 500 are set so that the ultraviolet emission unit 500a of the 500 and the ultraviolet emission unit 500a have an interval of Duv. The interval Duv in the step of driving the table according to the laminating step (S4) to the molding start position (S11) means that the ultraviolet UV emitted from the ultraviolet irradiation unit 500 is a liquid resin material Mf directly above the first molding layer 810. The reachable distance of the energy that can be cured. Then, the table 410 and the storage tank 300 are placed so that the relative positions of the table 410 and the storage tank 300 are such that the upper surface of the first molding layer 810 is at a position where the depth D _L2A is from the liquid level Sf of the liquid resin material Mf. Move. The depth D _L2A is the molding thickness of the connecting layer in the second mold molded product single layer.

(Ultraviolet irradiation process)
In the connection layer forming step (S121) of the ultraviolet irradiation step (S12) in the second layer in the resin molding method according to the present embodiment, as shown in FIG. 23, the depth D _L2A is maintained and the ultraviolet UV from the ultraviolet irradiation unit 500 The stage 200 is driven so that the ultraviolet irradiation unit 500 moves relative to the table 410 while irradiating, and constitutes the second molding mold layer 820 as the second molding molding single layer of the second layer. The connecting layer 820a is formed. At this time, a third connecting layer 823a as a boundary wall for forming a boundary between the first molded body 901 and the second molded body 902 constituting the molded body 900 shown in FIG. 11 (see FIG. 5). Is also formed. That is, the ultraviolet irradiation step (S12) includes a boundary wall layer forming step of forming the third connecting layer 823a as the boundary wall.

As shown in FIG. 23, in the resin molding method according to the present embodiment, in the connection layer forming step (S121) in the lamination step (S4), the first connection layer 821a, the second connection layer 822a, and the boundary wall The third connecting layer 823a is formed by curing the liquid resin material Mf with ultraviolet rays and UV rays. That is, the ultraviolet irradiation step (S12) includes a boundary wall layer forming step of forming the third connecting layer 823a as the boundary wall.

The third connection layer 823a is formed in a region corresponding to the boundary between the first molded body 901 and the second molded body 902, which are described above but constitute the molded body 900. The necessity of forming the boundary wall is set by the formation control data read in advance in the control unit 700 (see FIG. 1), but in the present embodiment, the molded body 900 shown in FIG. 11 is illustrated. Therefore, a third connection layer 823a serving as a boundary wall is formed.

When the connection layer 820a is formed, the process proceeds to the upper layer forming step (S122). In the upper layer forming step (S122), a table 410 as shown in FIG. 24, the relative positions of the reservoir 300, the upper surface of the connection layer 820a becomes the depth D _L2B from the liquid surface Sf of the liquid resin material Mf position The table 410 and the storage tank 300 are moved so as to be. The depth D _{L2 B} is the thickness of the upper layer laminated on the connection layer 820a.

Then, the liquid resin material Mf is cured by ultraviolet UV irradiation from the ultraviolet irradiation unit 500 on the connection layer 820a to form the upper layer 820b. In the upper layer 820b, the boundary wall is not formed on the third connection layer 823a, which is the boundary wall formed by the connection layer 820a in the present embodiment. Therefore, the upper layer 820b composed of the first upper layer 821b and the second upper layer 822b is formed by the upper layer forming step (S122).

The upper layer 820b formed by the upper layer forming step (S122) and the connecting layer 820a previously formed by the connecting layer forming step (S121) form a second second layer as a second molded product single layer. A mold layer 820 is formed. Then, the molding region 820s as the cavity of the second layer is formed by the second molding mold layer 820. The molding region 820s of the second layer sandwiches the molding region of the third connecting layer 823a, which is a boundary wall, with the first molding region 82As as the first cavity region and the second cavity region as the second cavity region. 2 Molding regions 82Bs and.

When the upper layer 820b is formed by the upper layer forming step (S122), the process proceeds to the upper layer stacking number confirmation step (S123). In this example, the form of the two-layer structure of the connection layer 820a and the upper layer 820b is illustrated. Therefore, the number of upper layers stacked is one, which is the same as the number of upper layers of the formation control data read into the control unit 700 (see FIG. 1) in advance (YES). Therefore, the ultraviolet irradiation step (S12) is completed, and the process proceeds to the next single-layer injection molding step (S3).

(Single layer injection molding process)
When the process shifts to the single-layer injection molding step (S2), the first injection molding step execution necessity confirmation step (S21) is first executed.

(First injection molding process execution necessity confirmation process)
In the first injection molding step execution necessity confirmation step (S21), the second molding as the second molded product single layer of the second layer from the formation control data read in advance into the control unit 700 (see FIG. 1). It is determined whether or not the first injection unit 610 needs to be driven when the layer 920 is molded. In the present embodiment, since it is a resin molding method of the molded body 900 having the first molded body 901 formed by the resin material Mp1, the first injection molding step execution necessity confirmation step (S21) is the first injection. It is determined that the injection of the resin material Mp1 is executed (YES) from the part 610, and the table 410 is driven to the injection molding start position.

(Drive the table to the injection molding start position by the first injection part)
As shown in FIG. 25, the injection molding start position of the first injection portion for driving the stage 200 so that the injection port 612b of the first injection portion 610 is arranged at the injection start position as a relative position with respect to the table 410. Drive (S22) is executed. At this time, the stage 200 is not driven in the Z direction, and the depth (D _L1 + D _L2 ) from the liquid level Sf of the liquid resin material Mf to the forming surface 410a is maintained, and the first injection molding step (S23) is performed. Will be migrated.

(First injection molding process)
In the first injection molding step (S23), as shown in FIG. 25 and FIG. 26 of the enlarged view of part B shown in FIG. 25, a second layer molded product single layer forming step from the injection port 612b by a predetermined pressure. A first injection molding step in which the resin material Mp1 is injected and filled into the first molding region 82As forming the molding region 820s which is a cavity formed in the second molding mold layer 820 formed by (S1). (S23) is executed.

The resin material Mp1 injected toward the first molding region 82As cools and solidifies, and the second molding layer 921 is formed. At this time, the injected plasticized resin material Mp1 is suppressed from invading the second molding region 82Bs into which the Mp2 of the second material, which will be described later, is injected by the third connecting layer 823a which is the boundary wall. .. That is, the molding region of the third connecting layer 823a may regulate and form the boundary region between the first molded body 901 and the second molded body 902 when forming the single-layer molded layer. it can.

The resin material Mp1 is injected and filled in the first molding region 82As, the first molding layer 921 of the second layer is formed, the first injection molding step (S23) is completed, and the second injection molding step is required. The process proceeds to the rejection confirmation step (S23).

(Second injection molding process execution necessity confirmation process)
The second injection molding step execution necessity confirmation step (S24) related to the laminating step (S4) is the second from the second injection unit 620 as in the first injection molding process execution necessity confirmation step (S21). The necessity of driving the resin material Mp2 as the material of the above is determined from the formation control data read in advance in the control unit 700 (see FIG. 1) whether or not the second injection unit 620 needs to be driven. In the present embodiment, since it is a resin molding method of the molded body 900 having the second molded body 902 formed by the resin material Mp2, the second injection molding step execution necessity confirmation step (S24) is the second injection. It is determined that the injection of the resin material Mp2 is executed (YES) from the part 620, and the table 410 is driven to the injection molding start position.

(Drive the table to the injection molding start position by the second injection part)
As shown in FIG. 27, the injection molding start position of the second injection portion for driving the stage 200 so that the injection port 622b of the second injection portion 620 is arranged at the injection start position as a relative position with respect to the table 410. Drive (S25) is executed. At this time, the stage 200 is not driven in the Z direction, and the depth ( _DL1 + D _L2 ) from the liquid level Sf of the liquid resin material Mf to the forming surface 410a is maintained, and the second injection molding step (S26) is performed. Will be migrated.

(Second injection molding process)
In the second injection molding step (S26), as shown in FIG. 27 and FIG. 28 of the enlarged view of part C shown in FIG. 27, a second layer molded product single layer forming step is performed from the injection port 622b by a predetermined pressure. A second injection molding step in which the resin material Mp2 is injected and filled into the second molding region 82Bs forming the molding region 820s which is a cavity formed in the second molding mold layer 820 formed in (S1). (S26) is executed.

The resin material Mp2 injected toward the second molding region 82Bs cools and solidifies, and the second molding layer 922 of the second layer is formed. At this time, the injected plasticized resin material Mp2 molds the third connecting layer 823a, which is the boundary wall of the first molding layer 921 formed by the first injection molding step (S23) executed earlier. It is connected to the end portion 921a formed in the region to form a second molded layer 920 as a so-called two-color molded second molded product single layer. The resin material Mp2 is injected and filled in the second molding region 82Bs, the second molding layer 920 is formed by forming the second molding layer 922 of the second layer, and the second injection molding step (S26) is completed. , The process proceeds to the step of confirming the number of layers (S3).

(Layered number confirmation process)
In the single-layer injection molding step (S2) immediately before the stacking number confirmation step (S3), the stacking number confirmation step (S3) for determining whether the N layers have been laminated is executed. In the stacking number confirmation step (S3) according to the above-mentioned stacking step (S4), the number of laminated molded product single layers is the second molding mold layer 820 and the second molding layer 820 by the immediately preceding single layer injection molding step (S2). Since it is two layers of two molded layers 920, it is determined that it is smaller than N (NO), and the process proceeds to the laminating step (S4) again.

In the laminating step (S4) described above, the first in the first molded product single layer, the second molded product single layer, and the first molded product single layer and the second molded product single layer, The second, simply indicates the order, not the number of layers. For example, when the fourth molding layer 840 is laminated on the third molding layer 830, the third molding layer 830 is called the first molding single layer, and the fourth molding is performed. The mold layer 840 is called a second mold molding single layer. Similarly, when the fourth molded layer 940 of the fourth layer is laminated on the third molded layer 930 of the third layer, the third molded layer 930 is referred to as the first molded product single layer, and the fourth molded layer 940 is referred to as the first molded product single layer. It is called the second molded product single layer.

The laminating step (S4) is repeated a predetermined number of times, and as shown in FIG. 29, from the first mold layer 810 composed of the connecting layer 810a and the upper layer 810b, the connecting layer 8N0a and the upper layer 8N0b are formed. The first molded body 800 as a mold molded body in which N layers of molded products are laminated up to the Nth molding mold layer 8N0, and the inside space, so-called cavity, using the first molded body 800 as a molding mold. The resin material Mp1 and the resin material Mp2 are injected into the injection. The injected resin material Mp1 and the resin material Mp2 are composed of a first molding layer 910 composed of a first molding layer 911, a first molding layer 921, and a second molding layer 922. A molded body as a second molded body in which the second molded layer 920 is laminated up to the Nth molded layer 9N0 composed of the first molded layer 9N1 and the second molded layer 9N2 of the Nth layer. 900 and are formed.

In the molded body 900, as shown in FIG. 11, the first molded body 901 and the second molded body 902 are integrally formed, and although not shown in FIG. 29, the first molding of the first layer is formed. The first molded body 901 is formed by the first molding layer 9N1 of the Nth layer from the layer 911, and the second molding is formed by the second molding layer 9N2 of the second molding layer 922 to the Nth layer of the second layer. Body 902 is constructed.

In the molded body 900, each layer from the third connecting layer 823a included in the second molding mold layer 820 to the third connecting layer 8N3a included in the Nth molding mold layer 8N0 of the Nth layer. The third connecting layer contained in the molded product 900 remains inside the molded product 900. Then, it was determined that the process was performed in the stacking number confirmation step (S3) and the N layers were laminated (YES), and the first molded body 800 and the molded body 900 as the second molded body were taken out from the storage tank 300. Moved to the mold release process.

(Release process)
The mold release step (S5) is a step of separating the molded body 900 from the first molded body 800 and taking out the molded body 900. In the mold release step (S5), mold release by physical means, mold release by chemical means, or the like is used. As a physical mold release means, the first molded body 800 is destroyed by applying an impact with a hammer or the like, and high-pressure air is press-fitted into the boundary between the first molded body 800 and the molded body 900 to destroy the first molded body. Means such as separating the 800 and the molded body 900 can be applied.

As the chemical release means, it is preferable to apply a mold release means for separating the molded body 900 by immersing it in a solvent that selectively dissolves the ultraviolet curable resin constituting the first molded body 800. As a result, there is no risk of damaging the molded body 900, and the mold can be separated from the first molded body 800. As described above, the connection layers 823a, ..., 8N3a contained in the first molded body 800 remain inside the molded body 900.

The molded body 900 obtained by the resin molding method according to the present embodiment has the third connecting layers 823a, ..., 8N3a remaining in the second molded layer 920 to the Nth molded layer 9N0 which are the two-color molded portions. A joint portion between the first molded layers 921, ..., 9N1 and the second molded layers 922, ..., 9N2 is formed beyond the above, and the second molded body 900 is two-color molded with the resin materials Mp1, Mp2. The adhesion strength between the molded body 901 of 1 and the molded body 902 of the second molded body 902 can be ensured.

(Third Embodiment)
As a third embodiment, a method of forming a molded body 1900 to be molded based on the flowchart shown in FIG. 10 in the description of the resin molding method according to the second embodiment by using the resin molding apparatus 1000 according to the first embodiment. explain.

The molding method of the molded product 1900 according to the present embodiment is a method based on the flowchart of the resin molding method of the molded product 900 according to the second embodiment shown in FIG. 10, and is in the mold molded product single layer forming step (S1). The ultraviolet irradiation step (S12) as a liquid resin material curing step has a characteristic molding method. Therefore, the same components as those of the resin molding method according to the second embodiment are designated by the same reference numerals, and the description of the common steps will be omitted.

(Molded product single layer forming process)
In the resin molding method according to the present embodiment, the molded body 1900 shown in the external perspective view of FIG. 30 is molded. As shown in FIG. 30, the molded body 1900 as the second molded body has a first molded body 1901 having a cross-sectional shape of a first cross section 1901a formed by the resin material Mp1 as the first material, and a second molded body. It has the outer shape of a conical base having a second molded body 1902 having a cross-sectional shape of a second cross section 1902a formed by a resin material Mp2 as a material of 2, and a cross-sectional shape 1900a having an internal space and a bottom formed of the second molded body 1902. Illustrate a container.

In the resin molding method according to the present embodiment, the same method as the molding method of the first molding mold layer 810 and the first molding layer 910 in the resin molding method according to the second embodiment described above is used. A first molding layer 1810 and a first molding layer 1910 are formed. The present invention relates to a second molding method that has been transferred to the laminating step (S4) with the first molding layer 1810 as the first molding single layer and the first molding layer 1910 as the first molding single layer. The mold molding single layer forming step (S1) will be described.

(Molded product single layer forming process)
In the mold molding single layer forming step (S1) related to the second layer transferred from the laminating step (S4), as shown in FIG. 31, the connecting layer forming step (S121) included in the ultraviolet irradiation step (S121) is performed. It is executed to form the connecting layer 1820a, and then the upper layer forming step (S122) is executed.

As shown in FIG. 31, in the connection layer forming step (S121), the connection layer 1820a constituting the second mold layer 1820 as the second mold molded product single layer of the second layer is from the ultraviolet irradiation unit 500. The liquid resin material Mf is cured by ultraviolet UV irradiation to form a first connecting layer 1821a, a second connecting layer 1822a, and a third connecting layer 1823a forming a boundary wall.

The upper layer forming step (S122) is executed on the connecting layer 1820a to form the upper layer 1820b. In the upper layer forming step (S122), the first upper layer 1821b is laminated on the first connecting layer 1821a, the second upper layer 1822b is laminated on the second connecting layer 1822a, and the third upper layer 1823b is laminated on the third connecting layer 1823a. The upper layer 1820b is formed by being laminated.

FIG. 32 shows a partially enlarged view of part D shown in FIG. 31. As shown in FIG. 32, a region in which the resin material Mp1 and the resin material Mp2 are injection-filled, that is, a so-called cavity is formed in the second molding mold layer 1820 formed by executing the upper layer forming step (S122). To. That is, the molding region 1820s is composed of the space region between the first connection layer 1821a and the second connection layer 1822a, and the space region between the first upper layer 1821b and the second upper layer 1822b. .. The molding region 1820s is divided by a third connecting layer 1823a and a third upper layer 1823b, which are boundary walls, and the first molding region 182As as the first cavity region and the second cavity region as the second cavity region. The second molding region 182Bs is formed. Then, the process proceeds to the single-layer injection molding step (S2).

In the resin molding method according to the present embodiment, the third connecting layer 1823a formed by executing the connecting layer forming step (S121), and the third upper layer 1823b formed by executing the upper layer forming step (S122). A boundary wall layer forming step of forming a boundary wall is included in the ultraviolet irradiation step (S121).

In the resin molding method according to the present embodiment, from the second layer to the last Nth layer, the same manufacturing method as the resin molding method according to the second embodiment described above is used, and the single-layer injection molding step (S2) and thereafter are laminated. (S4) is repeated, and as shown in FIG. 33, from the first mold layer 1810 composed of the connecting layer 1810a and the upper layer 1810b, the Nth Nth composed of the connecting layer 18N0a and the upper layer 18N0b. A first molded body 1800 as a mold molded body in which N layers of molded products are laminated up to a molding mold layer 18N0, and a resin material Mp1 in an internal space, a so-called cavity, using the first molded body 1800 as a molding mold. , Resin material Mp2, and are injected. The injected resin material Mp1 and the resin material Mp2 are composed of a first molding layer 1910 composed of a first molding layer 1911, a first molding layer 1921, and a second molding layer 1922. A second molded layer 1920 is formed, and a molded body 1900 as a second molded body laminated from the Nth layer to the Nth molded layer 19N0 composed of the first molded layer 19N1 is formed.

As shown in FIG. 33, in the molded body 1900 according to the present embodiment, the first molded body 1901, the second molded body 1902, and the third connecting layers 1823a, 1833a, ... , 18n3a and the third upper layers 1823b, 1833b, ..., 18n3b are laminated, but the third connecting layers 1823a, 1833a, ..., 18n3a and the third upper layers 1823b, 1833b, ..., 18n3b The nth layer, which is the upper layer, is
n <N (integer of n> 0)
And.

As a result, in the mold release step (S5) described later, the molded product 1900 is immersed in a solvent that selectively dissolves the ultraviolet curable resin constituting the first molded product 1800 by using a chemical mold removing means. In the case of separation, since the third upper layer 18n3b of the nth layer of the uppermost layer is not exposed from the surface of the molded body 1900, the third connecting layers 1823a, 1833a, ..., 18n3a as the boundary wall left inside the molded body 1900, and It is possible to prevent elution of the laminated body of the third upper layers 1823b, 1833b, ..., 18n3b.

Then, it was determined that the process was performed in the stacking number confirmation step (S3) and the N layers were laminated (YES), and the first molded body 1800 and the molded body 1900 as the second molded body were taken out from the storage tank 300. The process proceeds to the mold removal step (S5). In the mold release step (S5), the first molded body 1800 is separated by physical means or chemical means as in the resin molding method according to the second embodiment, and the molded body 1900 can be obtained.

The molded body 1900 obtained by the resin molding method according to the present embodiment includes the first molded body 1901, the second molded body 1902, and the third connecting layers 1823a, 1833a, ..., 18n3a which are boundary walls. It is separated and molded by a laminate of the third upper layers 1823b, 1833b, ..., 18n3b. As a result, when the performance of the affinity or adhesion between the resin material Mp1 as the first material and the resin material Mp2 as the second material for forming the molded body 1900 is not high, or the resin material Mp1, Even when there is a large difference in the glass transition point of Mp2, the third connecting layers 1823a, 1833a, which are the boundary walls cured by ultraviolet UV using, for example, an epoxy resin in the liquid resin material Mf, ... , 18n3a and the third upper layers 1823b, 1833b, ..., 18n3b form an adhesive wall (adhesive layer) between the resin material Mp1 and the resin material Mp2, and the two colors of the resin materials Mp1 and Mp2. It is possible to secure the adhesion strength between the first molded body 1901 of the molded molded body 1900 and the second molded body 1902.

By using an epoxy-based resin for the boundary wall, even resin materials Mp1 and Mp2 having a difference between the boundary wall and the crow transition point can be chemically bonded, and the epoxy-based resin has a functional group designed. Therefore, it is possible to design a structure that can obtain high adhesiveness depending on the types of resin materials Mp1 and Mp2.

100 ... base, 200 ... stage, 300 ... storage tank, 400 ... molding part, 500 ... energy ray irradiation part (ultraviolet irradiation part), 610 ... first injection part, 620 ... second injection part, 700 ... control Unit, 1000 ... Resin molding device.

Claims (10)

The stage and
With the water tank installed on the stage
The energy ray irradiation part that irradiates the energy ray and
A first injection part that plasticizes a first material that is a synthetic resin and ejects it from an injection port, and a second injection part that plasticizes a second material that is a synthetic resin and ejects it from an injection port. At least
The stage, the energy ray irradiation unit, and the driving means capable of relatively three-dimensionally moving the first injection unit and the second injection unit are provided.
The storage tank is provided with a table that can be driven at least in the direction of gravity, and stores a liquid cured resin material containing an energy ray-curable resin that is cured by the energy rays.
A resin molding device characterized by this. The energy rays emitted from the irradiation unit cure the cured resin material to form a layered first molded product.
One or both of the first material ejected from the first injection portion and the second material ejected from the second injection portion are cured to form a layered second molded product. Formed,
A first molded body in which the first molded product is laminated in the direction of gravity and a second molded body in which the second molded product is laminated in the direction of gravity are formed.
The resin molding apparatus according to claim 1. In the first molded product, a cavity for forming the second molded product is formed, and in the second molded product, at least one or both of the first material and the second material are contained in the cavity. Injected and filled in
The resin molding apparatus according to claim 2. The resin molding apparatus according to any one of claims 1 to 3, wherein the energy ray is ultraviolet rays. The resin molding apparatus according to any one of claims 1 to 4, wherein the synthetic resin is a thermoplastic resin. A liquid cured resin material containing an energy ray-curable resin stored in a storage tank installed on a stage is irradiated with energy rays, and the energy ray-curable resin is cured to form a single-layer molded product single layer. Molded product single layer forming process and
A first material, which is a plasticized synthetic resin, is injected from a first injection portion, and the first cavity region constituting the cavity of the molded product single layer is filled and solidified to solidify the molded product. A first single-layer injection molding step to form a layer,
A second material, which is a plasticized synthetic resin, is injected from a second injection portion, and the second cavity region constituting the cavity of the molded product single layer is filled and solidified to solidify the molded product. A second single-layer injection molding step to form a layer,
A mold molding laminating step of laminating on a first mold molding single layer formed by the mold molding single layer forming step and forming a second mold molding single layer by the mold molding single layer forming step. ,
The first single-layer injection molding step and the second single-layer injection molding step are laminated on the first molded product single layer formed by the first single-layer injection molding step, and the first single-layer injection molding step and the first. Including a single-layer injection molding step of 2 and a molded product laminating step of forming a second molded product single layer by
The mold molding laminating step is repeated a predetermined number of times, and the mold molding single layer is laminated with a predetermined number of layers.
The molded product laminating step is repeated a predetermined number of times to form a molded product laminated and filled in the cavity of the molded product.
A resin molding method characterized by this. The mold molding single layer forming step is
A boundary wall layer forming step of forming a boundary wall formed by curing the cured resin material at the boundary between the first cavity region and the second cavity region is included.
The resin molding method according to claim 6, wherein the resin molding method is characterized. Including a mold release step of releasing the molded product from the mold molded product.
The mold release step dissolves the mold.
The resin molding method according to any one of claims 6 or 7. The resin molding method according to any one of claims 6 to 8, wherein the energy ray is ultraviolet rays. The resin molding method according to any one of claims 6 to 9, wherein the synthetic resin is a thermoplastic resin.

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