JPH0760728A - Molding of three-dimensional molded object - Google Patents

Abstract

PURPOSE:To easily mold a three-dimensional molded object having a complicated shape by applying a first dry material to a reference surface in predetermined thickness and removing a part thereof to form a recessed part and filling the recessed part with a separate dry material to solidify one of both materials. CONSTITUTION:A curable material 1 is applied to the bottom surface plate becoming a reference surface 20 of a form 21 in a layered state and the material of the part where a cylindrical recessed part is formed of the applied material 1 is removed to form the recessed part 11. After the recessed part 11 is filled with a non-curable material 2, the curable material 1 is cured to be demolded. Therefore, a molded object 10 can be molded with high accuracy. As a result, the molded object 10 having a complicated shape can be easily molded without using a master mold.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a three-dimensional molded body such as a concrete molded body, a sintered body for a ceramic molded body, a ceramic molded body, a metal molded body, a mold or a plastic molded body.

[0002]

2. Description of the Related Art For example, in the case of expressing a pattern on the surface of a panel or a block with unevenness, conventionally, the only method has been to prepare an original mold in advance or carve the panel or block directly with a router or the like. There wasn't. Also in the case of manufacturing a mold, conventionally, the only method has been to prepare and mold the original mold in advance.

[0003]

However, when the original mold is prepared, the cost of the original mold is too high, so that the cost becomes very expensive when the small amount is produced. Further, when carving, the manufacturing process is troublesome and the cost is very high. Therefore, the present invention was developed for the purpose of expressing a three-dimensional pattern on a part or the entire surface of each of the above-mentioned various molded products in a layer having a predetermined thickness by using a dry powder or granular material.

[0004]

According to a first aspect of the present invention, there is provided a method for molding a three-dimensional molded body, wherein a dry first material is layered by a predetermined thickness on a reference surface on which the molded body is to be molded. Part of the material is removed to form a recess, the recess is filled with another dry material different from the first material, and either the first material or the other material is solidified.

[0005]

EXAMPLES To form a molded article by the method of the present invention, the dry first material and the different material to be layered on the reference surface are both granular materials, and either the first material or the different material. One is a curable material and the other is a non-curable material. The curable material includes any of water, oil, lubricating binder, solvent, curing agent, plasticizer, water, oil, lubricating binder, solvent, curing agent, plasticizer, even if it contains at least one of water, oil, lubricating binder, solvent, curing agent and plasticizer. Use a dry one that is not kneaded and can be easily loosened and fed onto the reference surface. The non-curable material includes water, oil, a lubricant, a solvent, and one or more types of release agents, including water, oil, a lubricant, a solvent, and a release agent. Use a dry product that is not kneaded and can be easily loosened and fed onto the reference surface. 1 to 5 show a molded body 10 molded by the method of the present invention, and FIGS. 1 to 4 show a circular recess 1
1 or a molded body having a convex portion 12, FIG. 5 is a molded body having a pattern in which a tree is expressed as a concave portion, and the molded body of FIG. 1 is expressed by a cylindrical concave portion 11 penetrating both sides. The molded body of FIG. 2 has a columnar molded body, and the molded body of FIG. 3 has a backing layer 4 integrally on the back of the molded body of FIG. The molded body of FIG. 4 is the same as that of FIG.
The backing layer 3 for closing the concave portion 11 is integrally provided on the back of the molded body. The molded body shown in FIG. 5 has recesses expressing tree trunks, branches, and leaves, and the recesses 11 expressing trees penetrate through the front and back. The shape of the three-dimensional molded body produced by the method of the present invention is not limited to a circular concave or convex portion, a tree pattern, or the like, and a flower pattern, a dot photograph, or any other shape can be formed.
For convenience of explanation, a method of forming a three-dimensional molded body having the above-mentioned circular concave or convex portion and a tree pattern will be described.

In order to mold the molded body of FIG. 1, as shown in FIG. 6A, the curable material 1 is layered on the bottom plate of the mold 21 serving as the reference surface 20, and among the layered materials, The material of the portion where the cylindrical concave portion is to be formed is sucked, blown off, and removed by dropping or the like to form the concave portion 11 as shown in FIG. 6B. The concave portion is filled with the non-curable material 2 and layered. The material is solidified and demolded, and any uncured material is removed. Since the concave portion is filled with the non-curable material 2 and the curable material 1 is solidified, the molded body can be molded with high precision. When forming the recessed portion 11, if a sheet mask 22 for forming the recessed portion having a circular opening is applied onto the hardened layer as shown in FIG. 7, the recessed portion 21 can be accurately formed without removing excess powder particles. Can be formed. In addition, different powders and granules can be put into the concave portion 11 by using the same mask, and the material can be accurately put into the concave portion through the opening to form the non-cured layer.

In order to mold the molded body of FIG. 2, as opposed to FIG. 6, as shown in FIG. 8, the non-curable material 2 is layered on the bottom plate of the mold 21 serving as a reference surface, and layered. The material of the portion to be formed into a cylindrical shape is sucked, blown off, and removed by dropping or the like to form a concave portion 11 as shown in FIG. 8B, and the concave portion 11 is filled with the curable material 1 and hardened. The material is solidified and demolded, and any uncured material is removed. Since the curable material is surrounded and hardened by the non-curable material, a cylindrical molded body can be molded with high accuracy. When forming the recess 20,
When the sheet mask 22 for forming the concave portion having the circular opening shown in FIG. 7 is applied onto the non-cured layer, the concave portion 20 can be accurately formed without removing excess powder or granular material. or,
In order to put the curable powder or granules into the concave portion 11, it is preferable to use the same mask so that the material can be accurately put into the concave portion from the opening portion to form a hardened layer.

To form the molded body of FIG. 3, the backing layer 3 is used.
A curable material is layered with the bottom plate of the mold 21 capable of molding as a reference surface (FIG. 9A), and the material of the layered material where the cylindrical recess 11 is to be formed is sucked and blown off,
Remove it by dropping etc. to form the recess 11 as shown in FIG.
The concave portion is filled with the non-curable material 2 (FIG. 9C), and the backing curable material 3 is filled thereover (FIG. 9D), and the curable material and the backing curable material which are layered first are solidified together. ,
Demold and remove any uncured material remaining. As another molding method, as shown in FIG. 10A, the backing curable material 3 is filled in the mold in a predetermined thickness in advance, and the backing curable material 3 is used as a reference surface, and the curable material 1 is placed thereon. To a certain thickness, and except for a part of this curable material,
Can be formed, and then the concave portion 11 is filled with the non-curable material 2 (FIG. 10B), and these curable materials are integrally hardened and can be molded even if demolded. In any of the molding methods, since the concave portion is filled with the non-curable material, the concave portion is accurately finished.

To produce the molded body of FIG. 4, the backing layer 4 is used.
Using the bottom plate of the mold 21 capable of forming a layer as a reference surface, the non-curable material 2 is layered, and the layered material of the layered material where the cylindrical shape is to be formed is sucked, blown off, dropped, etc. 11A to form the concave portion 11 as shown in FIG. 11A, the concave portion is filled with the curable material 1, and the backing curable material 3 is filled on the concave portion 11 (FIG. 11B). Material 1 and backing curable material 13 are solidified together, demolded, and uncured material, if any, is removed. As another molding method, as shown in FIG. 12, a backing curable material 3 is filled in a mold in a predetermined thickness in advance, and the backing curable material is used as a reference surface, and the non-curable material 2 is placed on the backing curable material. A layer having a certain thickness is applied (FIG. 12A), a concave portion 11 is formed by removing a part of the non-curable material, and then the concave portion 11 is filled with the curable material 1 and these curable materials are solidified together. It can be molded even if it is removed from the mold. In either method, since the curable material is surrounded by the non-curable material, the convex portion is finished accurately.

In order to manufacture the molded body of FIG. 5, the curable material 1 is layered on the bottom plate of the mold 21 serving as the reference surface as in the case of FIG. 6A, and is expressed as shown in FIG. After placing the insertion type mask corresponding to the trunk or branch of the tree on the layered curable material, insert the mask as shown in FIG. 14A to suck, blow off, or drop the curable material in the mask. By removing it to form the concave portion 11, the concave portion is filled with the non-curable material 00 expressing the trunk or branch of the tree (Fig. 14B), and when the mask is insoluble, it is removed, and as shown in Fig. 14B. In order to create a non-hardened layer that expresses the trunks and branches of trees, and to further express the leaves of trees, as shown in FIG. Mask 2
5 is placed, an insertion-type cell dense body mask is inserted as shown in FIG. 14C, a sheet mask 25 having tree leaves as openings is placed thereon, and the curable material and non-curable material are passed through the openings of the sheet mask. The curable material is suctioned, blown off, and removed by dropping or the like to form a concave portion 11 corresponding to a tree leaf, and the concave portion is filled with a non-curable material expressing the leaf of the tree. If the mask is insoluble, remove it. As shown in FIG. 15D, the curable material is hardened after expressing the trunk, branches and leaves of the tree. The non-hardening material is the concave part that forms the trunk, branches, and leaves of the tree.
Since 5 is satisfied, the pattern of the recess can be accurately expressed.
Although an insertion type mask corresponding to the trunk or branch of the tree is used in FIGS. 13 and 14, a sheet mask may be used.
Prior to the sheet mask that expresses the leaves of the tree, a recess is formed using a sheet mask in which the trunks and branches of the tree have openings, and these recesses are filled with a non-hardening material that expresses the trunks and branches of the tree. Then, put a sheet mask on which the leaves of the tree are openings, and suck and blow off the curable material and the non-curable material through the openings to remove by dropping etc. to form the recesses 11 corresponding to the tree leaves. , The concave portion may be filled with a non-curable material 2 expressing a tree leaf, and when the cell dense body and the mask are insoluble, the curable material may be removed to harden the curable material. Can be used. If the mask is soluble, it need not be removed. Further, it is also possible to form recesses in a dot shape or fill the recesses with a robot or the like. In either case, the mold is removed after curing, and if the non-curable material remains, it is removed, and the three-dimensional molded body is taken out.

In order to mold a molded body by the method of the present invention, the dry first material and the different material to be layered on the reference surface are both granular materials and either the first material or the different material. One is a curable material and the other is a non-curable material. Dry curable materials include water, oil, even if it contains at least one of water, oil, lubricant binder, solvent, curing agent, plasticizer from absolutely dry.
Use a dry one that is not kneaded with any of a lubricant binder, solvent, hardener, or plasticizer, and that can be easily loosened and supplied onto the reference surface. The backing material may be a dry curable material or a curable material kneaded with at least one of wet water, oil, a lubricating binder, a solvent, a curing agent and a plasticizer. Alternatively, other materials, for example, boards such as metal, wood, cement, glass, and ceramics, or sheets such as paper, non-woven fabric, woven cloth, and plastics can be used. When boards or sheets are used as the backing material, the boards or sheets serve as the reference surface. Further, the material may be layered and integrated by using various existing moldings as a reference surface. As the above-mentioned various materials for producing the molded body, different materials or colors, finishes such as gloss and texture are used depending on the molded body to be molded.

[0012] The dry curable material for molding a concrete molded body is cement powder or a simple substance of resin,
Alternatively, the main component is a mixture thereof, and further, a mixture obtained by adding a pigment or fine aggregate to them. A dry non-hardening material is at least one of various powders and particles that does not mix with cement or resin and does not harden as it is or when pressure is applied, and can be easily loosened and removed. , Wood chips, rock powder or granules, glass powder or granules, ceramic powder or granules, new ceramic powder or granules, metal powder or granules, plastic powder or granules, plant nut powder or granules Is a main component, and oil or a release agent is included or applied if necessary. In addition, the curable material for the backing is mainly composed of cement powder, resin alone, or a mixture thereof, or a mixture of them and fine aggregate, and if necessary, pigment or coarse aggregate. A mixture containing one or both of various fibers, which may be a dry material like the pattern material, or a wet material such as ready-mixed concrete kneaded with water or the like. In addition, if necessary, use wood chips as aggregate or fine aggregate for the curable material, crushed stone or powder of granite or marble, slag, light-reflecting particles, inorganic hollow bodies such as shirasu balloons, crushed particles of ceramics. Or crushed powder, Nucerax grains or powders, powders or grains of metals or other mineral substances, or other substances may be mixed, or a setting hardening accelerator, a waterproofing agent, an expanding agent or other admixtures may be mixed. The above-mentioned various fibers include metal fibers, carbon fibers, synthetic fibers, glass fibers and the like. Then, to harden the curable material in the mold, etc., put all the materials into the mold and then leave it as it is, or add water in a necessary amount, but when using a wet backing material together, backing material Reduce the amount of water in consideration of the water that oozes out. Also, other backing materials, such as metal,
Boards such as wood, cement, glass, and ceramics, or sheets such as paper, non-woven fabric, and woven cloth may be solidified together.

[0013] The sintering base material of the ceramic molded body and the dry curable material for molding the ceramic molded body include powders or grains of clay, rock or glass, powders or grains of new ceramics, powders or grains of fine ceramics. , One or more of glaze, or a mixture of these with a pigment and a colorant as a main component, and even if it contains water or a lubricating binder since it is absolutely dry, it is not kneaded with water or a lubricating binder. , Which can be easily loosened and supplied. A dry non-curable material is one that does not harden even when pressure is applied, does not harden at the temperature of the applied heat even if heat is applied, or burns off at the temperature of the applied heat. Various powders that can be removed,
At least one of the grains, such as soil, sand, wood chips, rock powder or grains,
Glass powder and granules, ceramic powder and granules, new ceramic powder and granules, metal powder and granules, powder and granules of high carbon content materials, plastic powder and granules, paper pulp, plant nut powder and granules At least one of the main components, if necessary water, oil,
A lubricant or the like is included or applied. Further, the curable material for backing is one or more of clay, rock or glass powder or particles, new ceramic powder or particles, fine ceramic powder or particles, or a mixture of these with a pigment or colorant. May be a dry one or a wet one kneaded with water or a lubricating binder. The curable material may be mixed with inorganic hollow bodies such as shirasu balloons, crushed particles or crushed powder of ceramics, powders or particles of metal or other mineral substances, various foaming agents, anti-flow agents. , Fining agents, lubricants, binders, adhesion promoters and other additives may be mixed. The above-mentioned powder or particles of the high carbon content material are carbon powder or particles, coke powder or particles, pitch powder or particles, coal powder or particles, or the like. Then, in order to harden the curable material in the mold, etc., put all the materials in the mold, etc. and add it as it is or add the necessary amount of water or a lubricating binder, give plasticity, pressurize and demold However, if it is a non-hardening material that does not harden or burns off at the temperature of the applied heat, remove it as it is, and if it is another non-hardening material, remove it and use it as a base material to sinter or to set a refractory setter, etc. After all the materials are put in the mold, they are heated to melt or fuse, and they are integrated and then demolded. Alternatively, a curable material is layered on a metal plate, a glass plate, a ceramics plate, a ceramics plate, or the like, and is heated and melted or fused to be integrated with the plate. By these methods, a crystalline glass molding or the like can be obtained.

The dry curable material for molding the mold is at least one of mountain sand, silica sand and special sand, and any one of a binder, a self-hardening binder and a thermosetting resin. The main component is the added mixture or at least one of mountain sand, silica sand, and special sand coated with a thermosetting resin. A dry non-curable material is a binder,
Various powders that do not mix self-hardening binder and thermosetting resin,
It is at least one of the particles, and it does not solidify as it is, it does not solidify when pressure is applied, or it does not solidify at the temperature of the applied heat and can be easily removed. , Soil, sand, wood chips, rock powder and grains, glass powder and grains, ceramic powder and grains, new ceramic powder and grains, metal powder and grains, high carbon content material powder and grains, plastic powder At least one of corn, grain, and plant nut powder or grain is used as a main component, and water, oil, a solvent, a plasticizer, a release agent, or the like is contained or applied as necessary. or,
The curable material for the backing is mainly composed of a mixture of at least one of mountain sand, silica sand and special sand, and one of a binder, a self-hardening binder and a thermosetting resin. As with the curable material, it may be a dry material or a wet material kneaded with water or the like.
If necessary, a secondary binder such as starch or sodium alginate, and various additives such as coke powder, pitch powder, coal powder, and wood powder are added to the curable material. Further, the above-mentioned binder and self-hardening binder are clay, bentonite, water glass, cement, gypsum, ethyl silicate, phenol resin, furan resin, urethane resin, drying oil, etc., and thermosetting resin. Is a phenol resin or other thermosetting resin, and is used by mixing with at least one of mountain sand, silica sand, and special sand, or by coating them in advance. Further, the powder or granules of the high carbon content material are carbon powder or granules, coke powder or granules, pitch powder or granules, coal powder or granules, or the like. Then, in order to harden the curable material in the mold, etc., put all the materials into the mold and then leave it as it is, pressurize it, contact it with gas, heat it, or add water in a necessary amount. Add.

The dry curable material for forming the sintering base material of the metal compact is one or more of various metal powders or grains, powders or grains of various alloys, or a mixture of these with a lubricant. Even if the mixture contains the mixture as a main component and the lubricant is completely dried, it is not kneaded with the lubricant and can be easily loosened and supplied. A dry non-curable material means at least one of various powders or particles that will not harden even if pressure is applied or that will be burned off at the temperature of the applied heat even if heat is applied, and soil, Sand, rock powder and grains, glass powder and grains,
Ceramic powder and granules, New ceramic powder and granules,
At least one of metal powder and granules, powder and granules of high carbon content material, plastic powder and granules, paper pulp, wood chips, and nut and plant powder and granules is used as a main component, and if necessary, water, oil and lubricant. Etc. are included or applied. Further, the curable material for backing is mainly composed of one or more kinds of various metal powders or particles, powders or particles of various alloys, or a mixture of these and a lubricant, which may be dry or lubricant. It may be a wet mix. Incidentally, zinc stearate or other substances may be used as the lubricant, and various substances may be added to the curable material as a binder or an additive. The above-mentioned powder or particles of the high carbon content material are carbon powder or particles, coke powder or particles, pitch powder or particles, coal powder or particles, or the like. Then, in order to harden the curable material in the mold, etc., in the case of a non-curable material that puts all the materials into the mold etc., pressurizes and demolds, and burns off at the temperature of the applied heat As it is, in the case of other non-curable materials, it is removed, and this is used as a base material and sintered. Alternatively, a curable material is layered on a metal plate, a glass plate, a ceramics plate, a ceramic plate, etc., and the plates are sintered together.

The dry curable material for molding a plastic molded body is mainly composed of various plastic powders or granules, or a mixture of these with pigments and colorants,
Even if it contains a plasticizer, solvent, etc., it is not kneaded with the plasticizer, solvent, etc. and can be easily loosened and supplied.Dry non-curable material means various plastic powders or granules. Doesn't mix, does it harden even if pressure is applied,
Or, it is one that does not harden at the temperature of the applied heat and can be easily removed, and contains at least one of various inorganic material powders or particles as the main component,
If necessary, a solvent, a plasticizer, a release agent, etc. may be included or applied. As the curable material for the backing, in addition to the above-mentioned dry material, a material kneaded with a wet plasticizer or solvent is used. As various plastic powders or particles of curable material, polyethylene, nylon, polypropylene, polycarbonate, acetal, polystyrene,
Epoxy, vinyl chloride, natural rubber, synthetic rubber, ABS,
PPO, EVA, fluorine resin and other thermoplastic and thermosetting resins can be used. If necessary, various additives such as a foaming agent, an antioxidant, a heat stabilizer, a cross-linking agent, and various powders and particles such as an inorganic material are added to the curable material. Then, in order to solidify the curable material, it is heated and melted or fused to form an integral body while pressurizing if necessary. By this method, they can be integrated to produce a three-dimensional molded article of polystyrene foam, a three-dimensional floor tile, and the like. In this case, other materials such as boards made of metal, wood, cement, ceramics, etc. or sheets made of paper, non-woven fabric, woven cloth, plastic etc. may be layered and integrated.

The material used in the present invention is not limited to the exemplified ones, but different materials may be used depending on the molded product.
One of the first material and another material is a curable material,
If the other is a non-curable material, various three-dimensional molded bodies can be formed.

The removal method for forming the recess is suction removal,
It may be removed by either blow-off removal or drop removal.Various methods can be used for suction removal, blow-off removal, and drop removal, respectively. Dotted recesses may be formed in the formed granular material layer by suction removal, blow-off removal, or drop removal.In this case, the degree of suction removal is not limited to vacuum suction, but vacuum suction, etc. may be selected as necessary. However, also in the case of removal by blowing out, the size of the recessed portion to be formed can be adjusted by adjusting the blowing amount and speed as necessary, various methods are possible, and the method is not limited to the example, but a mask is used. It is preferable to use the recesses to improve the efficiency.

When a mask is used, the boundary between the curable material and the non-curable material can be clearly expressed. The mask is a flat sheet or a plate, and the insertion type is inserted vertically inside the layered first material. For example, a frame body composed of a strip-shaped plate or sheet that is vertically partitioned along the contour of a pattern expressed as 23 in FIG. 13, a tubular small section (square or honeycomb shape with a certain height as shown in FIG. ) May be used in combination, or any of the Hayashi three-dimensional body 26 in which innumerable standing pieces stand from a supporting sheet such as a cloth, a mesh or the like, or a combination thereof may be used. The height of the insertion-type mask is preferably at least equal to or higher than the thickness of the powder or granular material layer to be removed. If the mask is a flat sheet or plate, it may be applied to the layered first material, and if it is a frame, cell dense body or Hayashi three-dimensional, it may be inserted into the layered first material, or in advance. It may be placed on the reference plane. For example, in the case of the molding method of FIGS. 6, 9, and 14 in which the first material comes into contact with the bottom of the mold, the frame body 23 or the cell dense body 24 is placed on the bottom of the mold before the material is added. Ya, Hayashi 3D
6 may be accommodated, and the material may be put inside or outside the frame, in the small sections of the cell dense bodies, or in the forest intervals of the standing pieces of the forest solid. If the frame body, cell dense body, or Hayashi solid is made of a material that does not dissolve in water, etc., remove it at a suitable time after filling the recess with another material, or mold the molded body before completely hardening. If the mask dissolves in water or the like, for example, if it is made of wafer, water-soluble vinylon, water-soluble plastics, etc., it may be left as it is. Also, the standing piece 26a of the Hayashi three-dimensional body 26 is a support sheet 26b.
In the case of standing with water-soluble glue or the like, the upright piece 26a may be left in the molded body and the support sheet 26b may be peeled from the molded body. In the drawing, the standing piece 26a of the Hayashi three-dimensional shape shows a thin protrusion like a pin for convenience, but in addition to this, a small piece that stands elongate,
Alternatively, fibers raised by flocking, brushing, adding hair, or piles formed by knitting or loops such as loops may be used, and it is desirable that thin standing pieces stand densely from the surface of the supporting plate or supporting sheet. . Further, in the case of using a flat mask, when the material is removed while applying pressure to the mask, the material causes a bridge between the mask and the reference surface, so that only the opening portion by the mask can be removed cleanly. Further, in the case of an insertion mask, a bulky mat is laid on the reference surface and the insertion mask is pressed against the mat to remove the material, whereby a recess can be formed neatly. In addition, if a cut is made in the insertion type mask, it can be used for curved surfaces. The formation of the concave portion by the mask and the suction can be performed by using the above-mentioned various masks and changing the degree of suction and the suction method. Further, as another method of forming the concave portion, there is also a method of dropping a part of the granular material layer. For example, there is a method of applying a mask or inserting it and then inverting it together with the material, dropping the material from the opening of the mask to make a recess, and in this way, continuously invert it on the drum etc. to make a recess and then invert it. Alternatively, another material can be filled. In addition, the plate-shaped mask and the insertion type mask are united in advance and inverted in the surrounding frame, and after the layers are layered in the frame, the form plate bottom plate and the like are pressed and inverted by an appropriate method. The granular material layer surrounded by the insertion type mask remains, and the granular material layer layered on the opening portion of the plate-shaped mask is dropped and removed to form a concave portion, so that the concave portion should be filled with another material. Good. As another method of making the recesses, there is also a method of removing by blowing it off.For example, the reference surface is made to have air permeability, and the insertion type mask is placed on the air permeable mat and layered, and air is applied from outside the mat. May be blown off and the powder or granules in the mask may be blown off to form a recess. In this case, it may be solidified as it is or may be solidified by re-layering. The degree of suction removal is not limited to vacuum suction, and vacuum suction or the like may be selected as necessary. Similarly, in the case of removal by blowing out, the degree may be determined as necessary. Further, when the mask is an insert type, when the mask is removed, vibration of the vibrator causes the material to collapse and help fill the back of the mask.

As the reference surface, a reference surface at the time of layering and a reference surface at the time of integral curing may be properly used. For example, after forming a recess on the layering surface at the time of layering, the layer is inverted as it is or after refilling the recess. Alternatively, the patterns may be moved to be expressed and then solidified together.
Further, it is also possible to use a mold having a depth capable of being layered a plurality of times, retake the reference surface a plurality of times, repeat layering, formation of recesses, and filling, and then harden the curable material, as shown in FIG. ,
A three-dimensional molded body having a complicated shape can be formed. By these methods, not only the exemplified ones but also various molded products can be formed. still,
For the sake of convenience, the bottom plate of the formwork or the lining material filled in the formwork has been used as the reference surface, but the top surface of the roll of the manufacturing machine, the endless mat or sheet, etc. may be used as the reference surface. Can be continuously molded.

When the reference surface is placed on the bottom plate in the mold and the mold is composed of the separable bottom plate and the peripheral frame, the curable material and the non-curable material are put in the mold and the existing For example, by placing on a concrete molded product and sliding the bottom plate out from under the peripheral frame, the molded product can be overlaid on the existing product and solidified together. Also, when the bottom plate cannot be separated from the surrounding frame, the upper surface of the formwork is closed with a plate, etc., the formwork and plate are inverted and placed on an existing object with a plate, and the plate is slid and removed from under the formwork. By doing so, it is possible to stack the molded product on the existing product and solidify it in the same manner.

In any case, if a deformable mat or a deformable part or all of the mold is used as the reference surface, a finished surface other than a flat surface can be formed.

Further, when molding, by laying a non-woven fabric or other water-absorbing or oil-absorbing mat on the reference surface or the curable material layer, excess water, oil, lubricating binder, plasticizer, Solvents can be absorbed by the mat or excess water, oil, lubricating binders, plasticizers, solvent of one part of the material can be replenished to the other part lacking it, and ,
Make the oil, lubricant binder, plasticizer and solvent uniform. Also, by this, surface water (auxiliary agent): cement (resin)
Since the ratio is small, the strength of the molded product can be improved. Furthermore, when a breathable mat is used for pressure molding, deaeration is assisted to form a dense molded body. In addition, when solidified, vibration or pressure makes the material solid, and the strength can be improved. Furthermore, various long fibers or short fibers can be put in the layer of curable material or backing material, or wire mesh or rebar can be put in to reinforce. As a backing material, molding by papermaking method or extrusion molding method can be used. By using the body and various boards and sheets, it is possible to deal with molded articles for various purposes such as construction panels and boards, wall sheets, and tiles.

[0024]

EFFECTS OF THE INVENTION According to the present invention, various three-dimensional molded bodies such as concrete molded bodies having irregularities, sintered bodies for ceramic molded bodies, ceramic molded bodies, metal molded bodies, molds, and plastic molded bodies can be easily molded. You can Molds such as molds and powder metallurgy can be made directly without making an original mold. Especially in the case of single product production, the productivity is extremely high, and conventionally, molds that give detailed expression based on photographs etc. Although it was difficult to directly form a molded product such as a metal molded product or a metal molded product, it has become possible to directly mold a dot-shaped photographic-like molded product. Also, a concrete molded body,
In the case of ceramics moldings etc., it was difficult to make fine deep engravings, but now it is possible to easily mold moldings with similar irregularities by single product production, even in the case of dot-shaped photo-like moldings, etc. Even if the surface of the molded body is abraded, the carved shape is so deep that the expressed shape does not disappear or become unsightly. And, since the curable material and the non-curable material are dry materials, each material collapses and can be filled tightly without gaps, the boundary of the shape can be expressed finely, and the finished solid is very beautiful. . Further, it is very troublesome to separately supply the powder and granular materials addressed to one kind so as not to lose the shape and express the shape, but in the present invention, the powder and granular material having a large area is used as the reference surface. First, layering is performed, and then a recess is formed by removing a part of the layered powder and granules, and the recess may be filled with another material, so that a three-dimensional molded body having a complicated pattern or shape can be easily molded. . In addition, since it is possible to easily and continuously mold from small to large ones, it is possible to mold it into a plate shape, etc.
Panel-shaped three-dimensional moldings such as cast panels, ceramics, and concrete can be made.

[Brief description of drawings]

FIG. 1 is a perspective view of a first example of a molded product molded by the present invention.

FIG. 2 is a perspective view of a second example of a molded product molded by the present invention.

FIG. 3 is a partially cutaway perspective view of a third example of a molded product molded by the present invention.

FIG. 4 is a perspective view of a fourth example of a molded product molded by the present invention.

FIG. 5 is a partially cutaway perspective view of a fifth example of a molded product molded by the present invention.

6A is a sectional view showing a manufacturing sequence of the molded body of FIG. 1. FIG. 2B is a cross-sectional view showing the manufacturing sequence of the molded body of FIG.
3C is a cross-sectional view showing the manufacturing sequence of the molded body of FIG.

7 is a perspective view of a mold and a mask used to mold the molded body of FIG.

8A is a cross-sectional view showing a molding sequence of the molded body of FIG. 2. FIG. (B) is a cross-sectional view showing a molding sequence of the molded body of FIG.
FIG. 3C is a cross-sectional view showing the molding sequence of the molded body of FIG.

9A is a cross-sectional view showing a molding sequence of the molded body of FIG. 3. FIG. (B) is a cross-sectional view showing a molding sequence of the molded body of FIG.
FIG. 3C is a cross-sectional view showing the molding sequence of the molded body of FIG. D is a cross-sectional view showing the molding sequence of the molded body of FIG.

10A is a cross-sectional view showing another molding sequence of the molded body of FIG. 3. FIG. (B) is a sectional view showing another molding sequence of the molded body of FIG.

FIG. 11A is a sectional view showing a molding sequence of the molded body of FIG. (B) is a cross-sectional view showing a molding sequence of the molded body of FIG.

12A is a sectional view showing another molding order of the molded body of FIG. 4. FIG. (B) is a sectional view showing another molding sequence of the molded body of FIG.

13 is a perspective view showing a use state of the insertion-type mask for molding the molded body of FIG.

14A is a cross-sectional view showing a molding sequence of the molded body of FIG. 5. FIG. (B) is a cross-sectional view showing a molding sequence of the molded body of FIG. 6C is a cross-sectional view showing the molding sequence of the molded body of FIG. 5.
D is a cross-sectional view showing the molding sequence of the molded body of FIG.

FIG. 15 is a perspective view of a sheet mask used for molding the molded body of FIG. 5 and a cell dense body.

FIG. 16 is a perspective view of a sixth example of a molded product molded by the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Curable material (cured layer) 2 Non-curable material (non-cured layer) 3 Backing curable material (backing layer) 10 Molded body 11 Recessed portion 12 Convex portion 20 Reference surface 21 Form frame 22 Sheet mask 23 Insertion mask 24 Cell density Collection 25 Sheet mask 26 Hayashi 3D

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B44C 3/10 C03B 19/00 Z

Claims (1)

[Claims] 1. A dry first material having a predetermined thickness is layered on a reference surface on which a molded body is to be molded, a part of the layered first material is removed to form a recess, and the recess is formed. A method for molding a three-dimensional molded body, which comprises filling with another dry material different from the first material and hardening either one of the first material and the different material.