JPS60141888A - Manufacture of shell forming layer for vacuum forming plastic sheet - Google Patents

Abstract

PURPOSE:To pierce easily suction holes of a desired diameter at desired positions by forming a shell forming layer on a master model having many fine wires attached to the surface and by removing the wires to pierce pores in the shell forming layer. CONSTITUTION:Many fine wires 6, 6', 6'' are attached to the desired positions of the surface of a master model 5 made of wood, plastics or the like. The wires 6, 6', 6'' are metallic wires, and synthetic fibers or the like may be used. Electric conductivity is provided to the model 5 by a conventional method, and a shell forming layer 1 is formed on the surface of the model 5 by electroforming. The layer 1 is then released from the model 5, and the wires 6, 6', 6'' set in the layer 1 are drawn out to obtain a shell forming layer 1 for vacuum-forming a plastic sheet. The layer 1 has many pores 4, 4' as suction holes.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a shell forming layer for vacuum forming a plastic sheet.

A vacuum forming method is one of the methods for manufacturing plastic molded products having unevenness.

For example, as shown in FIG. 1, this method involves placing a plastic sheet 2 for molding over the concave portion of a shell forming layer 1 made of metal or resin, and applying suction from the outside of the shell forming layer with a vacuum pump 3. The plastic sheet 2 is molded to match the shape of the shell forming layer 1. Therefore,
The shell forming layer is equipped with hundreds to thousands of suction holes to exhaust the air between the shell forming layer and the plastic sheet, etc., so that no traces of these suction holes remain on the vacuum-formed product. , the suction hole must have an extremely small diameter of 0.2 mm or less.

Conventionally, in order to provide the suction holes in the shell forming layer, for example, a thin metal drill has been used to make the holes.

However, since the diameter of the suction hole is very small, the aperture is also thin, and there is a drawback that the thread easily breaks during operation.

There is also a possibility that the damaged cone may remain in the shell cambium. Also, at a depth υ greater than the length of the drill, it is not possible to process the part within the radius of the chuck that fixes the drill.

Furthermore, drilling work requires skill.

On the other hand, drilling using a laser has also been carried out. However, with this method, it is not possible to drill holes in areas where the surface of the shell forming layer is sloped, in areas near the walls of the shell forming layer, or in areas deeper than the focal length of the laser. Furthermore, there is a practical problem in that the cost is high.

The present invention has been made in view of the above, and an object of the present invention is to provide a method for manufacturing a shell forming layer for vacuum forming of a plastic sheet having a large number of suction holes, which overcomes the conventional drawbacks.

That is, in the present invention, after attaching a large number of fine wire materials to a master model, a shell forming layer is formed on the master model, and then the fine wire materials are removed from the shell forming layer to form a large number of pores in the shell forming layer. The gist of the present invention is a method of manufacturing a shell forming layer for vacuum forming a plastic sheet, which is characterized by providing a shell forming layer for vacuum forming of a plastic sheet.

Embodiments of the present invention will be described in detail below with reference to the drawings.

In FIG. 2, a master model 5 of a molded product, such as a lining material for automobiles, is made of wood, plastic, plaster, or the like.

In addition, when the shell forming layer described later is produced by electroforming, silicon or the like may be used from the above master model.

Next, a large number of thin wires 6, 6' are attached to the surface of the master model 50 by implanting the thin wires 6 at desired positions on the master model 5 or bonding the thin wires 6' to the model using instant adhesive or the like.

This thin wire material has water resistance and chemical resistance in order to withstand shell forming layer production processes such as electroforming and resin lamination, and is also stretchable and can maintain its shape in hot water (40°C to 50″C). Thin wire material 6, 6', 6 is preferable.
As ', synthetic fibers such as nylon and vinylon, glass fibers, natural fibers, especially single fibers thereof, metal wires such as iron, aluminum, copper, etc. are used.

An excellent feature of the present invention is that desired pores, ie, suction holes, can be extremely easily provided in the shell forming layer by arbitrarily selecting the diameter of the fine wire material of the forceps.

For example, holes with an inner diameter of 0.1 to 0.05 m are also possible.

By using the λ thin wire material as the curved thin wire material 6'', it is possible to form the curved pores 4' in the shell forming layer 1, which was impossible with conventional methods, in the process of producing the shell forming layer described later.
It is possible to provide the

A large number of fine wire materials 6, 6 on the surface obtained as described above.
The master model 5 with ' and 6' attached thereto is subjected to conductive treatment and electroformed using a conventional method. A shell forming layer (electroformed shell forming layer) 1 is formed on the surface of a master model 50 to which a large number of thin wire members 6, 6', 6' are attached by electroforming.

At this time, the electroforming is performed in such a way as to fill the thin wire materials 6, 6', 6'.
, 6' will later form pores. Therefore, by selecting the diameter and attachment position of the thin wire material, pores of a desired diameter can be easily provided at a desired position.

When the shell forming layer is a resin shell forming layer, the resin layer is formed by casting or coating a resin on the master model 5 on which a large number of thin wire members 6, 6', 6' are attached. do.

As a result, a shell forming layer (resin shell forming layer) 1 is formed on the surface of the master model 6 to which a large number of thin wire members 6, 6', 6' are attached.

As in the case of electroforming, the thin wires 6, 6', 6' will later form pores.

Next, the above-mentioned shell forming layer (electroformed shell forming layer, resin shell forming layer) 1 was removed from the master model 5, and the fine wire material 6°s/, eI planted in the shell forming layer 1 was pulled out. yoυ, fine bottle pores 4 as shown in Figure 3,
A shell forming layer 1 for vacuum forming of a plastic sheet having a large number of 4' can be easily obtained. The pores 4 form suction holes 4 for vacuum forming dust.

The shell forming layer 1 thus obtained is set in a mold 7 as shown in FIG. 1 according to a conventional method, and the space is filled with granular materials 8 such as granular aluminum (=lamb), and a binder is poured in. Then, a plastic sheet vacuum molding mold is manufactured.

However, after removing dust from the shell forming layer 1, the thin wire material 6,
The process of pulling out 6' and 6' may be performed after the above-mentioned process of setting the mold and filling the granules.

As is clear from the above, the present invention involves forming a shell forming layer by electroforming or resin layer formation on a master model with a large number of thin wires attached to the surface, and then removing the thin wires to form a shell forming layer. Since it is a device that provides holes, it is possible to easily create linear or curved fine suction holes of the desired diameter at the desired location, making it extremely easy to form shell forming layers for plastic sheet vacuum forming compared to conventional methods. Moreover, it has the advantage of being able to be manufactured at low cost.

[Brief explanation of drawings]

Fig. 1 is a schematic cross-sectional view showing a plastic sheet vacuum forming process, Fig. 2 is a schematic cross-sectional view of an embodiment of the manufacturing method according to the present invention, and Fig. 3 is a schematic cross-sectional view of an example of a shell for vacuum forming a plastic sheet. . 1... Shell forming layer 4,4'... Pore (suction pore)
5...Master model 6, 6', 6'...
Fine wire material patent applicant Achilles Co., Ltd. (7) 457-

Claims (1)

[Claims] After attaching a large number of thin wire materials to a master model, a shell forming layer is formed on the master model, and then the thin wire materials are removed from the shell forming layer to provide a large number of pores in the shell forming layer. A method for producing a shell forming layer for vacuum forming a plastic sheet.