JPS60121022A - Die and its manufacture - Google Patents

Abstract

PURPOSE:To obtain a die light in weight, excellent in durability, and having high rigidity by reinforcing a shell, formed by metal spraying, by a layer of fiber- reinforced thermosetting resin and further backing it up by a composition of thermosetting resin. CONSTITUTION:A metallic layer of 0.1-40mm. thickness is formed on the surface of a prototype by spraying a metal, after providing releasing treatment to the surface of the prototype having a shape inverse to the surface shape of a die. A layer of fiber-reinforced thermosetting resin of >=0.5mm. thickness is formed on the metallic layer, and further a composition of themosetting resin is filled up in other parts, to complete a shape of the whole body. Then the die is obtained by releasing it from the prototype. Further, the layer of fiber-reinforced thermosetting resin is constituted of a carbon fiber and a composition of thermosetting resin.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a mold and a method for manufacturing the same. More specifically, it consists of a shell made by gold S4 thermal spraying, a fiber-reinforced thermosetting resin layer reinforcing the shell, and a thermosetting resin composition constituting the other parts. The present invention relates to a mold that is lightweight, highly durable, and easily manufactured, and a method for manufacturing the same.

Conventionally, many plastic molded products have been molded using molding methods such as injection, press, and transfer, but in order to use these molding methods, a mold is required, and in addition, it is difficult to change the shape of the plastic molded product. It is necessary to create a mold with a corresponding shape each time. However, manufacturing molds using the conventional cutting or electroforming techniques is very time consuming and therefore requires a long delivery time and has the drawbacks of being expensive. Furthermore, although the mold is often made entirely of metal, it also has the disadvantage of being difficult to handle due to its increased weight. In order to eliminate these drawbacks, a metal spraying method is used to create a shell that forms the mold surface, and this is filled with a resin composition or molten metal is poured to back it up. Although methods for manufacturing molds have been proposed.

These methods have problems such as insufficient rigidity of the mold, lack of durability, and almost no reduction in weight. Currently, the development of a mold and its manufacturing method is awaited.

In view of the current situation, the inventors of the present invention, Nagisa et al., have made extensive studies, and have found that by reinforcing the shell made by the gold aphrodisiac method with a fiber-reinforced thermosetting resin layer and backing it up with a thermosetting resin composition, Finding 1: It is possible to easily manufacture molds with excellent durability and high rigidity based on the amount of eaves.
This led to the present invention.

That is, the first object of the present invention is that the outermost layer of the mold surface is a metal layer with a thickness of An object of the present invention is to provide a mold in which the fiber-reinforced thermosetting resin layer is formed on the top layer of L5, and the other parts are made of a thermosetting resin composition.

Another object of the present invention is to provide a method for manufacturing a cotton mold.

The metal spraying used in the present invention is gas spraying.

It refers to a method such as arc spraying or plasma spraying in which a metal material is sprayed in a molten or semi-molten state to form a thermal spray coating. The material to be thermally sprayed is a single metal or an alloy such as iron, aluminum 2 stainless steel, zinc, copper, brass, copper 2, etc., and all metal materials generally used in thermal spraying can be used.

The thickness of the metal layer created by metal spraying is (), 1 to 4
It is 1 circle of 0 friends. If the thickness of the metal layer is less than 1.1 mm, the strength of the metal layer is insufficient and a durable mold cannot be obtained, which is undesirable.

On the other hand, if the thickness exceeds 40, the weight of the mold increases, and distortion due to thermal contraction of the sprayed coating is likely to occur, which is undesirable.

The fiber-reinforced thermosetting resin layer constituting the mold of the present invention is composed of a fibrous reinforcing agent and a thermosetting resin composition, and examples of the fibrous reinforcing agent include glass twill fiber, polyamide fiber, and carbon fiber. Materials commonly used in the field of fiber-reinforced thermosetting resins, such as gypsum fiber, sisal, or their mixtures, blends, or blends, are used, and their shapes include those preformed into a mat or cross shape. A roving type can be used. Among these fibrous hardening materials, carbon fiber is particularly preferred from the viewpoint of the rigidity and thermal conductivity of the resulting mold.

The thermosetting resin composition used in the present invention includes phenolic resin, epoxy resin, unsaturated polyester resin,
Vinyl ester resins, urethane resins, etc. can be mentioned, and these resins can be mixed with additives such as fillers, colorants, and curing agents.

The thickness of the fiber-reinforced thermosetting resin layer is 0.51 g or more. If the thickness of the layer is less than 0.5 mm, sufficient durability and rigidity cannot be imparted to the mold, which is undesirable.

As the thermosetting resin composition constituting the other parts, the same resin composition as that used for the fiber-reinforced thermosetting resin layer or a different resin composition is used from among the above-mentioned thermosetting resin compositions. can do.

If particles or powder of metal such as aluminum or iron are blended into this thermosetting 1ff-1 resin composition, the thermal conductivity of the entire mold will improve, which is desirable.
The purpose is to improve the overall strength of the mold.

Fever 6! It is also possible to mix a fibrous reinforcing material into the thermoplastic resin composition, and examples of these fibrous reinforcing materials include glass fiber, carbon fiber, two-stone kola fiber, sisal, and polyamide fiber.

A specific example of the method for manufacturing a mold according to the present invention is as follows:
The following methods can be mentioned.

First, a master mold having a shape that is an inversion of the surface shape of a mold is prepared, and the surface thereof is subjected to mold release treatment using a mold release agent or the like as necessary. Then, the metal is sprayed to a thickness of 0.1 to 4011 mm.
A metal layer 111 is formed. At this time, considering the adhesion between the mold and the metal to be sprayed, first spray a relatively low melting point metal such as tin or zinc, then aluminum, copper, etc.
A metal having a relatively high melting point such as iron or nickel may be thermally sprayed and laminated. In addition, in order to minimize distortion due to heat shrinkage of the exposed metal 1-, 1 m of gold was applied during thermal spraying.
It is desirable to take care so that the temperature of 1- does not rise too much.

After forming the metal layer in this way, Km fiber-reinforced thermosetting resin is applied to the metal layer using a thermosetting resin composition and a fibrous reinforcing material according to a general method such as drying up, spraying, etc. A resin layer is formed. Next, the fiber-reinforced thermosetting resin layer is cured, or before curing, the thermosetting resin composition is cast, hand laid up, sprayed up, etc. to form other necessary parts of the mold. Fill it using the method described above, and then harden the entire piece. At this time, in order to adjust the overall shape and increase the rigidity of the mold, the outer surface of the part other than the gold layer formed by thermal spraying may be covered with a metal plate such as copper, aluminum, iron, etc. .

After curing the thermosetting resin composition, the desired mold can be obtained by removing the p-type mold.

In addition, if you need two molds, one male and one female, you can use two separately created prototypes, or you can create one mold using the method described above, and then use the created mold as necessary. After forming a desired shape by combining auxiliary molds and the like, this can be used as a master mold to create another mold using exactly the same method.

As mentioned on stage, according to the present invention, a lightweight and highly durable mold with a structure in which a metal layer formed by thermal spraying is backed by a highly rigid fiber-reinforced thermosetting resin layer can be created. It can be obtained easily. below.

The present invention will be explained in more detail with reference to Examples. Note that all parts in the examples represent parts by weight.

Example 1 i After painting, # molding agent (Nippon Shokubai Chemical Industry Co., Ltd. 4)
Evolac EP-11 manufactured by Co., Ltd. was applied with a brush and dried at room temperature. Next, an arc spraying machine (manufactured by TAFA, USA,
375EFS) under typical conditions.
A metal layer is formed by thermal spraying to a thickness of 1111, and then a hardening agent is added to the carbon fiber (Torayca Cross C06343, manufactured by Toshiku Co., Ltd.) and epoxy resin (Araldite cW2, manufactured by Ciba Geigy Co., Ltd.) on the metal layer. (manufactured by Ciba Geigy, Inc., HY217) was used to form a carbon fiber-reinforced epoxy resin layer to a thickness of about 5 mm by a hand lay-up method. Next, metal layer and carbon #! X!
An aluminum plate with a thickness of 10 mm is attached to surround the fiber-reinforced epoxy resin layer, and 1 aluminum grain with a particle size of about 20 mesh is added to 100 parts of the mixture of the epoxy resin and the hardening agent in the space.
A resin composition mixed with 1 part of (+ A male mold was created using a nohi-shaped male mold with the surface reversed, following exactly the same procedure.The male and female molds thus obtained were combined, mounted on a press, and heated to a molding temperature of 145.
℃. Sheet molding compound (Nippon Shokubai Chemical Industry Co., Ltd.
When a tray was molded using Eporac Mat 2068E (manufactured by fM Co., Ltd.), a good molded product was obtained. Spread,
Although 500 trays were molded under the same conditions, all molded products were of good quality, and there were no abnormalities in the molds.

Claims (1)

[Claims] 1. The outermost layer of the mold surface is made by metal spraying and has a thickness of 0.
The inner layer in contact with the metal layer is a fiber-reinforced thermosetting resin layer with a thickness of 0.5 mm or more, and the other parts are made of a thermosetting resin composition. Type. 2. The mold according to claim 1, wherein the fiber-reinforced thermosetting resin layer is made of carbon fiber and a thermosetting resin composition. 3. The mold has a shape that is an inversion of the surface shape of the mold. After performing a mold release treatment on the surface of the master mold, a metal layer is thermally sprayed on the surface of the master mold to form a metal layer with a thickness of 0.1 to 40 mm, and then a fibrous reinforcing material is applied on the metal layer. A carbon fiber-reinforced thermosetting resin layer with a thickness of fl, 5 m or more is formed using a thermosetting resin composition, and other parts are filled with a thermosetting resin composition to shape the entire shape. 4. A method for manufacturing a mold, characterized in that the mold is demolded from a prepared original model; 4. The method for manufacturing a mold according to claim 3, wherein the fibrous reinforcing material is carbon fiber.