JPH11245239A - Production of template - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a temperate through which air in a cavity and air bubbles in a resin are easily vented when the resin is cast. SOLUTION: In a method for producing a template with a mold face with a negative shape corresponding to the surface shape of an aimed article by feeding a resin R into a cavity 4 of a matrix 1 consisting of a top mold 2 and a bottom mold 3 and with a mold face 31 with a positive shape corresponding to the surface shape of the aimed article and curing the resin therein, the resin R is fed into the cavity 4 of the matrix 1 under a condition where the matrix 1 is inclined.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a template such as a press template for a building board by a resin injection molding method.

[0002]

BACKGROUND OF THE INVENTION At present, a fiber-reinforced inorganic plate is often used as a building exterior plate. These inorganic plates are generally provided with a concavo-convex pattern on the surface in order to enhance the design and improve the commercial value. In particular, in recent years, the inorganic plate is provided with a concavo-convex pattern so as to have a tile or brick-like appearance.

[0003] Such an inorganic plate is produced by press-pressing a template having an uneven pattern on the surface of an uncured molded plate obtained by molding a raw material mixture. Is pressed to obtain a tile or brick-like inorganic plate in which grooves are formed vertically and horizontally.

[0004] Conventionally, as a template having such a concavo-convex pattern,
Metallic materials such as iron plates have been used, but since they are heavy, difficult to manufacture, and costly, those made of glass fiber reinforced thermosetting resin (FRP) have recently been generally used. ing. Such an FRP mold plate is advantageous in that it is lightweight and can be manufactured by a simple process of injecting a resin into a matrix and curing it.

[0005]

2. Description of the Related Art In the manufacture of a FRP template, usually,
A matrix 1P as shown in FIG. 7 is used. The matrix 1P
Is an upper mold 2P having a plurality of resin injection ports 21P, and a mold surface 31.
And a lower mold 3P having a concavo-convex pattern 311P on P. In order to manufacture a template using the master 1P, a glass fiber F is previously placed in the cavity 4P of the master 1P placed horizontally.
(Chopped strand mat) is inserted, and the thermosetting resin R is sequentially injected from the pressure feed pump 7P through the resin injection port 21P of the upper mold 2P to be cured.

[0006]

However, since the area of the mold surface of the mother die 1P is large, the air in the cavity 4P, particularly the air in the corners, hardly escapes during the resin injection in the above method, and the resin R is hardened by the cavity 4P. It does not completely cover the whole, and bubbles generated in the resin have no escape place,
There is a problem that the obtained template does not have a desired shape or that bubbles are formed in the template. In particular, when the glass fiber F is inserted into the cavity 4P, air is likely to be retained, and the problem becomes conspicuous.

[0007] In addition, a concave groove 311 P that is continuous vertically and horizontally is formed on a mold surface.
When using lower mold 3P in 31P, cavity 4P
The resin R injected into the groove 311P spreads along the continuous groove 311P without accompanying the glass fiber F, and the glass fiber F hardens without being filled in the groove 311P. There was sometimes. The ridge on the template is
Since it is a portion where a large stress is applied during pressing when manufacturing an inorganic plate, it is necessary to have a sufficient strength, but the ridges not including the glass fiber F are easily chipped, and the durability of the obtained template is reduced. There was a problem. Further, if the resin R fills the groove 311 P first, the groove 31
There is also a problem that the 1P portion slightly rises to form a weir, and the resin R subsequently injected is blocked by the weir and does not spread to a portion surrounded by the weir, and air tends to remain.

Accordingly, an object of the present invention is to provide a method of manufacturing a mold plate from which air in the cavity and bubbles in the resin are easily discharged at the time of casting the resin, and a case where a lower mold having a continuous concave groove is used. Another object of the present invention is to provide a method for manufacturing a template in which resin does not run ahead of the continuous groove.

[0009]

In order to solve the above problems, the present invention relates to a positive mold surface (31) comprising an upper mold (2) and a lower mold (3) and corresponding to the surface shape of an object. A method for manufacturing a mold plate (8) having a negative mold surface corresponding to the surface shape of the target object by injecting and curing the resin (R) into the cavity (4) of the matrix (1) having the mold (1). Wherein a resin (R) is injected into a cavity (4) of the matrix (1) while the matrix (1) is inclined. is there. The inclination angle (θ) of the matrix (1) is preferably from 10 ° to 45 °.

The upper mold (2) has a plurality of resin inlets (21).
a, 21b, 21c) are provided, and the position where the resin (R) is injected into the cavity (4) of the matrix (1) is set at a lower position by the inclination of the matrix (1). (21a)
It is preferable to inject the resin (R) while sequentially moving the resin (R) from the top to the upper resin injection port (21c).

In the method for manufacturing a template, the reinforcing fiber (F) is inserted into the cavity (4) of the matrix (1) in advance, and then the resin (R) is injected into the cavity (4). Is also good. The object may be a building board, and the template (8) may be a press template (8) for manufacturing a building board. Further, a positive groove (311) corresponding to the surface shape of the object is formed on the mold surface (31) of the lower mold (3), and the positive grooves (311) are continuous. Is also good.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. FIGS. 1 and 2 show a matrix that can be used in the method of manufacturing a template according to the present invention. The matrix 1
Is composed of an upper mold 2 and a lower mold 3, and the upper mold 2 and the lower mold 3
The space surrounded by defines the cavity 4. The upper mold 2 has resin inlets 21a, 21b with a valve 211,
A plurality of (in this case, a total of six) 21c are provided, and air vent pipes 22a, 22
b are connected two by two.

On the other hand, a continuous groove 311 composed of a vertical groove and a horizontal groove crossing the vertical groove is formed on the mold surface 31 of the lower die 3. The mating surface 32 of the lower mold 3 with the upper mold 2
In addition, a packing mounting groove is provided around the mating surface 23 of the upper die 2 with the lower die 3, and a packing 51 is mounted in the packing mounting groove. The upper mold 2 and the lower mold 3 are fixed by fastening the brackets 24 provided at the four corners of the upper mold 2 and the brackets 33 provided at the four corners of the lower mold 3 with bolts 52. Is done.

The material of the lower mold 3 is not particularly limited, but examples thereof include diallyl phthalate resin reinforced with fibers such as glass fiber, carbon fiber, ceramic fiber and rock wool, unsaturated polyester resin, styrene Resins, urea resins, melamine resins, synthetic resins such as phenolic resins, or inorganic materials such as ceramics, gypsum, silicates, and the like. Preferred materials include unsaturated polyester containing glass fibers or styrene-unsaturated polyester. And gypsum. On the other hand, the material of the upper mold 2 is not particularly limited, but is preferably a transparent material such as an acrylic resin, a polyethylene resin, a polypropylene resin, or a polyester resin from the viewpoint of transparency at the time of resin injection. preferable.

A method for manufacturing a press template for manufacturing a building board using the matrix 1 will be described. First, a release agent is applied to the mold surface 25 of the upper mold 2 and the mold surface 31 of the lower mold 3, and then the reinforcing fibers F are inserted into the mold surface 31 of the lower mold 3. As the reinforcing fiber, an inorganic fiber such as a glass fiber, a carbon fiber, and a ceramic fiber can be used, and it is preferable to use a glass fiber in terms of a reinforcing effect, dimensional stability, and raw material cost. The reinforcing fiber is preferably used as a chopped strand mat, but the chopped strand mat may be used in combination with a continuous strand mat, a roving cloth, a swirl mat, a felt, a needle punching mat, or the like. Alternatively, short fibers may be used as they are. Moreover, you may use in combination with metal fibers (wire mesh) etc. other than an inorganic fiber.

After the reinforcing fiber F is inserted, the upper mold 2 is connected to the lower mold 3
And the bracket 24 of the upper die 2 and the bracket 33 of the lower die 3 are fastened by bolts 52. In the present invention, the upper mold 2 and the lower mold 3 (master mold 1) fixed in this manner are inclined, and in this state, a resin is injected into the cavity 4 of the mother mold 1. Specifically, as shown in FIG. 1, the matrix 1 may be placed on the inclined base 6. At this time, it is preferable to incline so that the longitudinal direction of the matrix 1 is inclined, and the inclination angle θ
Is preferably 10 ° to 45 °. The inclination angle θ is 10 °
If it is less than 45 °, the effect of the present invention cannot be sufficiently obtained, and if it exceeds 45 °, it becomes difficult to inject the resin or the reinforcing fibers are biased. The valves 211 of the resin inlets 21a, 21b, 21c are opened in advance.

In the case of producing a press plate for building board production, thermosetting resins such as diallyl phthalate resin, unsaturated polyester resin, styrene resin, urea resin, melamine resin, phenol resin and the like are used as the resin. However, the present invention is not limited to this, and various thermoplastic resins can be used.

The above-mentioned resin (in the case of a thermosetting resin, a resin obtained by adding a curing agent to the thermosetting resin) is supplied to a pressure pump 7
From the mold 4 into the cavity 4. First, the forked resin injection pipe 71 connected to the pressure feed pump 7 is connected to the resin injection ports 21a, 21a (lower stage) of the upper mold 2, and the resin injection port 21 is
The resin R is injected into the cavity 4 through the holes a and 21a (FIG. 3). The resin R injected from the resin injection ports 21a, 21a
Along the inclination of the matrix 1, the air first flows down to the lower stage of the cavity 4, and at this time, the air in the lower stage of the cavity 4 is
a and 22a are discharged out of the cavity 4. The resin R
However, the lower part of the cavity 4 is filled and the air vent pipes 22a, 22a
When the air vent pipes 22a, 22a are
Close by. Since the matrix 1 is inclined, the resin R does not advance in the continuous groove 311 toward the upper side of the cavity 4.

When the resin R fills the lower part of the cavity 4, the resin R then goes back to the middle part of the cavity 4, and the air in the cavity 4 pushed by the resin R is released from the resin inlet 21b,
The air is discharged out of the cavity 4 from the air vent pipes 22b, 22b and the air vent pipes 22b, 22b. When the resin R fills the lower half of the middle stage of the cavity 4 and reaches the resin injection ports 21b, 21b, the resin injection from the resin injection ports 21a, 21a is stopped,
The valve 211 of the resin inlet 21a, 21a is closed.

Next, the resin injection pipe 71 connected to the resin injection ports 21a, 21a is removed, and the resin injection ports 21b, 21b are removed.
(Middle stage), and the resin R is injected into the cavity 4 through the resin injection ports 21b, 21b (FIG. 4). Resin inlet 21
The resin R injected from the b, 21b goes back to the upper middle stage of the cavity 4 and is pressed by the resin R.
The air is supplied to the resin inlets 21c, 21c and the air vent pipe 22b,
It is discharged out of the cavity 4 from 22b. The resin R is
Fill the entire middle stage of the cavity 4 and fill the resin injection ports 21c, 21c
When the temperature reaches, the resin injection from the resin injection ports 21b, 21b is stopped, and the valve 211 of the resin injection ports 21b, 21b is closed.

Further, the resin injection pipe 71 connected to the resin injection ports 21b, 21b is removed, and the resin injection ports 21c, 21b are removed.
c (upper stage), and the resin R is injected into the cavity 4 through the resin injection ports 21c, 21c (FIG. 5). Resin injection port
The resin R injected from 21b, 21b goes back to the upper stage of the cavity 4, and at this time, the air in the upper stage of the cavity 4 is discharged out of the cavity 4 from the air vent pipes 22b, 22b. When the resin R fills the upper stage of the cavity 4 and the air vent pipe 22
b, 22b, the resin injection from the resin injection ports 21c, 21c is stopped and the valve 21 of the resin injection ports 21b, 21b is stopped.
1 is closed, and the air vent pipes 22b, 22b are closed by the clips 221.

As described above, when the resin R is injected in a state where the matrix 1 is inclined, even when the area of the mold surface of the matrix 1 is large, or when the reinforcing fiber F is inserted. However, the air in the cavity 4 easily escapes, and the resin R completely spreads throughout the cavity 4. In addition, air bubbles generated in the resin R rise along the inclination of the upper mold 2, and rise in the resin injection port 21.
a, 21b, 21c and air vent pipe 22b,
Air bubbles are prevented from remaining in the resin R.

Further, the grooves 311, which are continuous vertically and horizontally, are formed in the mold surface 31.
Even when the lower mold 3 is used, the lower mold 3 is inclined and the resin R is injected in order from the lower resin injection port 21a. It does not run ahead of the continuous groove 311. Therefore, the resin R is
It is easy to enter the continuous groove 311 while entraining the reinforcing fiber F, and the groove 311 is filled with the resin R and the reinforcing fiber F. Further, the weir is not formed in the continuous groove 311 and the resin R flows well.

After the injection of the resin is completed, the resin is cured in that state. The resin is usually cured at room temperature, but may be heated if desired. After the resin has hardened, the bolts 52 fastening the bracket 24 of the upper mold 2 and the bracket 33 of the lower mold 3 are removed, and the upper mold 2 and the lower mold 3 are divided, as shown in FIG. The press template 8 is taken out. The obtained press die plate 8 is formed into a desired shape and does not contain air bubbles. Further, the press die plate 8 has a ridge 81 corresponding to the concave groove 31 of the lower die 3, but since the ridge 81 is filled with the reinforcing fiber F, the strength is high and the durability is excellent. .

Although the method of the present invention has been described with reference to the drawings, the present invention is not limited to the embodiments shown in the drawings, and various modifications can be made without departing from the scope of the present invention. it can. For example, the continuous concave groove 31 is formed on the mold surface 31 of the lower mold 3.
Instead of 1, various uneven patterns may be formed.
In addition, the number of resin injection ports of the upper mold 2 is not limited to six, and may be appropriately set according to the size of the mold surface area, the viscosity of the resin, and the like. Further, the resin injection port may be opened and closed with a stopper, a clip, or the like instead of the valve 211.

[0026]

According to the present invention, since air in the cavity and bubbles in the resin are easily discharged at the time of casting the resin, a mold plate having excellent shape stability and having no bubbles can be obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a matrix according to an example used in the present invention.

FIG. 2 is a perspective view of a matrix (upper and lower dies) according to an example used in the present invention.

FIG. 3 is a sectional view showing a manufacturing process (first step) of a template according to the present invention.

FIG. 4 is a sectional view showing a manufacturing step (second step) of the template according to the present invention.

FIG. 5 is a sectional view showing a manufacturing step (third step) of the template according to the present invention.

FIG. 6 is a perspective view of a template according to an example obtained by the method of the present invention.

FIG. 7 is a cross-sectional view illustrating a manufacturing process of a conventional template.

[Explanation of symbols]

 1, 1P: Master mold 2, 2P: Upper mold 21a, 21b, 21c, 21P: Resin injection port 211: Valve 22a, 22b: Air vent tube 23: Fitting surface 24: Bracket 25, 25P: Mold surface 3, 3P ... Lower mold 31, 31P ... Mold surface 311 ... Continuous concave groove 311P ... Concavo-convex pattern (Continuous concave groove) 32 ... Mating surface 33 ... Bracket 4,4P ... Cavity 51 ... Packing 52 ... Bolt 6 ... Incline stand 7,7P ... Press-feed Pump 71… Resin injection tube 8… Press template 81… Protrusion

Claims (6)

[Claims] 1. A resin is injected into a cavity of a matrix having an upper mold and a lower mold and having a positive mold surface corresponding to the surface shape of an object, and is cured to correspond to the surface shape of the object. A method for producing a template having a negative mold surface, wherein a resin is injected into a cavity of the matrix while the matrix is inclined. 2. The upper mold is provided with a plurality of resin injection ports, and the resin is injected in order from the lower resin injection port to the upper resin injection port due to the inclination of the matrix. The method for producing a template according to claim 1, wherein: 3. The method according to claim 1, wherein a reinforcing fiber is inserted into the cavity of the matrix in advance, and then a resin is injected into the cavity. 4. The method of manufacturing a template according to claim 1, wherein the object is a building plate, and the template is a press template for manufacturing a building plate. 5. The positive mold groove according to claim 1, wherein a positive concave groove corresponding to the surface shape of the object is formed on the lower mold surface. Manufacturing method of template. 6. The method for manufacturing a template according to claim 1, wherein the inclination angle of the matrix is 10 ° to 45 °.