JPS62187002A - Manufacture of master model for preparing foam molding tool - Google Patents

Manufacture of master model for preparing foam molding tool

Info

Publication number
JPS62187002A
JPS62187002A JP3020686A JP3020686A JPS62187002A JP S62187002 A JPS62187002 A JP S62187002A JP 3020686 A JP3020686 A JP 3020686A JP 3020686 A JP3020686 A JP 3020686A JP S62187002 A JPS62187002 A JP S62187002A
Authority
JP
Japan
Prior art keywords
cured resin
resin layer
mold
master model
molded product
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP3020686A
Other languages
Japanese (ja)
Other versions
JPH0579004B2 (en
Inventor
Shigeaki Ono
茂昭 小野
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Inoac Corp
Original Assignee
Inoue MTP KK
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Inoue MTP KK filed Critical Inoue MTP KK
Priority to JP3020686A priority Critical patent/JPS62187002A/en
Publication of JPS62187002A publication Critical patent/JPS62187002A/en
Publication of JPH0579004B2 publication Critical patent/JPH0579004B2/ja
Granted legal-status Critical Current

Links

Abstract

PURPOSE:To manufacture a master model easily in a short period of time by manufacturing a gypsum mold from a model foam molding, laminating and then integrating a cured resin layer on the surface of said gypsum mold. CONSTITUTION:The surface of a foaming molding 10 is coated and impregnated with polyester resin 12 to prevent the foam molding from being transformed. Then, releasant such as wax or the like is spread on the surface of a cured resin layer 12, and gypsum is poured into a wooden frame 14 to form an upper half 22. After dismantling the wooden frame 14, the upper half 22 and the molding 10 are placed upside down, with wooden frame 14 being fabricated again, and releasant is spread on the surface of the exposed cured resin layer 12. Then, gypsum is poured in to manufacture a lower half 26. Releasant is coated on both upper and lower halves 22 and 26 on which a cured resin layer 36 is formed, and said upper and lower are integrated with adhesive. After said process, gypsum model is destroyed and a master model is provided.

Description

【発明の詳細な説明】 (産業上の利用分野) この発明は、発泡成形型作製用マスターモデルの製造方
法に関する。
DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a master model for producing a foam mold.

(従来の技術) ポリウレタンフォーム等からなる発泡成形品を成形する
ための発泡成形型の作製には、発泡成形品形状からなる
マスターモデルが必要とされる。
(Prior Art) To manufacture a foam mold for molding a foam molded product made of polyurethane foam or the like, a master model consisting of the shape of the foam molded product is required.

ところで、従来におけるマスターモデルの製造方法は、
発泡成形品の図面に基づいて木材を切断、接合、研摩等
により発泡成形品形状とするものである。
By the way, the conventional method of manufacturing a master model is
The shape of the foam molded product is made by cutting, joining, polishing, etc. wood pieces based on the drawing of the foam molded product.

(発明が解決しようとする問題点) ところが、このようにして作製されたマスターモデルは
、そのモデルから一旦発泡成形型が作製された後は殆ど
不要であり、またこのマスターモデルは製品の形状に応
じて随時作成されるものであるから、その数量も膨大で
あり保管スペース等の関係から往々にして廃棄される。
(Problem to be solved by the invention) However, the master model produced in this way is almost unnecessary once a foam molding mold is produced from the model, and this master model is not suitable for the shape of the product. Since they are created as needed, their quantity is enormous, and they are often discarded due to storage space considerations.

しかし、このマスターモデルから作製された発泡成形型
も時日の経過に従って劣化し、予定耐用期間内に破壊す
ることもしばしばである。また、製品の受注量が予想以
上に増加することも時折生ずるところである。このよう
な場合、いずれにおいても短時日の期間内に対応するこ
とが必要又は望まれるものであるが、前述の如くマスタ
ーモデルを廃棄した場合にあっては、マスターモデルを
木材等から再作成せねばならず、迅速な対応が殆ど不可
能であった。
However, foam molds made from this master model also deteriorate over time and often break down within their expected service life. In addition, from time to time, the amount of orders for products increases more than expected. In any of these cases, it is necessary or desirable to respond within a short period of time, but if the master model is discarded as mentioned above, the master model must be recreated from wood, etc. It was almost impossible to respond quickly.

よって、本発明はこのような場合における必要なマスタ
ーモデルの迅速な製造方法を提供しようとするものであ
り、特には製品である発泡成形品を利用したマスターモ
デルの製造方法を提供しようとするものである。
Therefore, the present invention aims to provide a method for quickly manufacturing a necessary master model in such a case, and particularly provides a method for manufacturing a master model using a foam molded product. It is.

(問題点を解決するための手段) この発明は、 (イ)発泡成形品表面に含浸硬化樹脂層を形成する工程
、 (ロ)含浸硬化樹脂層が形成された発泡成形品をモデル
として、その形状を転写した型面を有する分割可能な石
膏型を作製する工程、 (ハ)分割した石膏型の型面に硬化樹脂層を積層する工
程、 (ニ)硬化樹脂層を合体させる工程、及び(ホ)その合
体物を石膏型から取り出す工程とから、発泡成形型作製
用マスターモデルの製造を行なうことを特徴とするもの
である。
(Means for Solving the Problems) This invention includes (a) a step of forming an impregnated cured resin layer on the surface of a foam molded product, and (b) a process of forming an impregnated cured resin layer on a foam molded product as a model. A step of producing a divisible plaster mold having a mold surface with a transferred shape; (c) a step of laminating a cured resin layer on the mold surface of the divided plaster mold; (d) a step of combining the cured resin layers; e) A master model for producing a foam mold is manufactured from the step of taking out the combined product from the plaster mold.

(実施例) 以下、車両用座席クッションパッドの発泡成形型作製用
マスターモデルの製造を例に上げ、その製造工程を示す
第1図乃至第8図の断面図あるいは部分断面図に基づい
てこの発明を説明する。
(Example) The present invention will be described below based on the cross-sectional views or partial cross-sectional views of FIGS. 1 to 8 showing the manufacturing process, taking as an example the manufacture of a master model for manufacturing a foam mold for a vehicle seat cushion pad. Explain.

(イ)含浸硬化樹脂層の形成工程(第1図)発泡成形品
10、この例にあってはウレタンフオームからなる車両
用座席クッションパッドの表面に、硬化性樹脂、例えば
ポリエステル樹脂をハケ等により塗布して含浸させ、含
浸硬化樹脂層12を形成する。なお、発泡成形品lOが
表面に皮膜(スキン)を有する場合には、硬化性樹脂の
含浸に先立ち、アセトン等の溶剤により皮膜を溶解除去
しておくのが、硬化性樹脂の含浸を良好とする点で好ま
しい。この含浸硬化樹脂層12の形成により発泡成形品
10表面の剛性が高まるので、その後の工程において発
泡成形品10の変形が生じなくなる。
(B) Step of forming an impregnated hardened resin layer (Fig. 1) A hardening resin, such as a polyester resin, is applied to the surface of the foamed molded product 10, in this example a vehicle seat cushion pad made of urethane foam, by brushing or the like. The impregnated cured resin layer 12 is formed by coating and impregnating. If the foamed molded product IO has a skin on its surface, it is recommended to dissolve and remove the skin with a solvent such as acetone before impregnating with the curable resin to ensure good impregnation with the curable resin. It is preferable in that it does. Formation of this impregnated cured resin layer 12 increases the rigidity of the surface of the foamed molded product 10, so that deformation of the foamed molded product 10 does not occur in subsequent steps.

又、その含浸硬化樹脂層12は、硬化性樹脂の含浸によ
るものであるために、発泡成形品10の外形寸法が増大
することもなく、正確な外形を維持することが可能とな
る。
Further, since the impregnated cured resin layer 12 is formed by impregnation with a curable resin, the outer dimensions of the foamed molded product 10 do not increase, making it possible to maintain an accurate outer shape.

(ロ)石膏型の作製工程(第2図乃至第5図)含浸硬化
樹脂層12が形成された発泡成形品10を、第2図の如
く、その周囲に隙16を残して木枠14内に配置する。
(B) Plaster mold production process (Figs. 2 to 5) The foamed molded product 10 on which the impregnated cured resin layer 12 has been formed is placed inside the wooden frame 14 with a gap 16 left around it as shown in Fig. 2. Place it in

その隙16は50關以上とするのが好ましい。18は発
泡成形品10の支持台であり、発泡成形品lOノ形状に
応じて適宜用いられる。
The gap 16 is preferably 50 degrees or more. Reference numeral 18 denotes a support base for the foamed molded product 10, which is used as appropriate depending on the shape of the foamed molded product 10.

そして、隙16に粘土20を詰める。このとき、粘土2
0の上面20a(見切りライン)から上において、発泡
成形品10にアンダーカット部がないようにする。
Then, the gap 16 is filled with clay 20. At this time, clay 2
0 above from the upper surface 20a (parting line) of the foam molded product 10 so that there is no undercut portion.

次いで、発泡成形品IOの露出した硬化樹脂層12表面
に、ワックス等の離型剤を塗布し、その後第3図の如く
木枠14内に石膏を流し込み、硬化させて石膏型上半体
22を作製する。石膏の厚みは100+mn以上とする
のが好ましい。そして、木枠14の解体及び粘土の除去
を行なった後、第4図の如く石膏型上半体22及び発泡
成形品10を反転させ、石膏型上半体22の合わせ面2
2aに位置決め用凹部24を形成する。
Next, a mold release agent such as wax is applied to the exposed surface of the cured resin layer 12 of the foam molded product IO, and then plaster is poured into the wooden frame 14 as shown in FIG. Create. The thickness of the plaster is preferably 100+mn or more. After dismantling the wooden frame 14 and removing the clay, the upper half of the plaster mold 22 and the foam molded product 10 are turned over as shown in FIG.
A positioning recess 24 is formed in 2a.

次いで、第5図の如く再度木枠14を石膏型上半休22
周囲に組み立て、発泡成形品lOの露出した硬化樹脂層
12表面に離型剤を塗布する。そして木枠14内に石膏
を流し込み、硬化させて石膏型下半休26を作製する。
Next, as shown in FIG.
A mold release agent is applied to the exposed surface of the cured resin layer 12 of the foamed molded product 10. Then, plaster is poured into the wooden frame 14 and hardened to produce a lower plaster mold 26.

石膏型下半休26には、その作製時に前記位置決め用凹
部24と嵌合する凸部28が、合わせ面に形成される。
A convex portion 28 that fits into the positioning recess 24 during manufacture is formed on the mating surface of the lower half of the plaster mold 26.

石膏の硬化後、木枠14を分解し、石膏型上下半体22
.26を分離させて石膏型内から発泡成形品10を除去
する。このようにして作製された石膏型は、発泡成形品
lOをモデルとして、その外形状を転写してなる型面を
有するものである。その後、必要に応じて石膏型の型面
をサンドペーパー等で暦き、表面を平滑にする。
After the plaster hardens, the wooden frame 14 is disassembled and the upper and lower halves of the plaster mold 22 are assembled.
.. 26 is separated and the foamed molded product 10 is removed from the plaster mold. The plaster mold thus produced has a mold surface formed by copying the outer shape of the foamed molded product IO as a model. Then, if necessary, sand the surface of the plaster mold with sandpaper to make the surface smooth.

(ハ)硬化樹脂層の積層工程(第6図)まず、分割した
石膏型上下半体22.26の型面に離型剤を塗布する。
(c) Lamination process of cured resin layer (FIG. 6) First, a mold release agent is applied to the mold surfaces of the divided upper and lower halves 22 and 26 of the plaster mold.

次にその型面にポリエステル系ゲルコート30をハケ等
により塗布する。そのゲルコート30の硬化後、エポキ
シ樹脂とタルクとの粘土状混合物32を、ゲルコート3
0上に数mm厚で積層する。そして、未だ硬化してない
エポキシ樹脂とタルクとの混合物32上に、エポキシ樹
脂が塗布されたガラスクロス34を所定枚数積層する。
Next, a polyester gel coat 30 is applied to the surface of the mold by brushing or the like. After the gel coat 30 has hardened, a clay-like mixture 32 of epoxy resin and talc is applied to the gel coat 30.
0 to a thickness of several mm. Then, a predetermined number of glass cloths 34 coated with epoxy resin are laminated on the mixture 32 of epoxy resin and talc that has not yet been cured.

ガラスクロス34は300mm角程度を月参るのが作業
上都合よく、又、その積層枚数は、5〜10枚程度とす
るのが普通である。このゲルコート30、エポキシ樹脂
とタルクとの混合物32、及びガラスクロス34は、エ
ポキシ樹脂の硬化により一体化し、硬化樹脂層36を形
成する。
It is convenient for the work that the glass cloth 34 is about 300 mm square, and the number of layers is usually about 5 to 10. The gel coat 30, the mixture 32 of epoxy resin and talc, and the glass cloth 34 are integrated by curing the epoxy resin to form a cured resin layer 36.

(ニ)硬化樹脂層の合体工程(第7図)硬化樹脂層36
の所定部に補強用リブ38を設ける。
(d) Cured resin layer combining step (Fig. 7) Cured resin layer 36
A reinforcing rib 38 is provided at a predetermined portion.

この補強用リブ38の設置は、ベニヤ板にガラスクロス
を巻き付けたものを用い、それをエポキシ樹脂等の接着
剤により硬化樹脂層36上に固着するのが簡便である。
The reinforcing ribs 38 can be easily installed by using a glass cloth wrapped around a plywood board and fixing it onto the cured resin layer 36 with an adhesive such as epoxy resin.

勿論硬化樹脂層36の硬化前に補強用リブを配置しても
よい。この補強用リブ38の高さは、硬化樹脂層36.
36の合体により形成されるマスターモデルの内部空間
の高さよりも、僅かに高いものとする。
Of course, reinforcing ribs may be arranged before the cured resin layer 36 is cured. The height of this reinforcing rib 38 is set to 36.
It is assumed that the height is slightly higher than the height of the internal space of the master model formed by combining 36.

次に、石膏型上下半体22.26のいずれかの合わせ面
における硬化樹脂層36周囲に、接着剤を逃がす為の溝
40を形成する。
Next, a groove 40 for letting the adhesive escape is formed around the cured resin layer 36 on either mating surface of the upper and lower plaster mold halves 22, 26.

そして、硬化樹脂層36の合わせ部及び補強用リブ38
の先端に、エポキシ樹脂等からなる接着剤42を付着し
、その後石膏型の上下半体22.26を、その合わせ面
の位置決め用凹部24と凸部28とを合わせて閉型し、
硬化樹脂層36.36の合体接着を行なう。この時、補
強用リブ38は、上下の硬化樹脂層36.36の内面に
よって押圧、圧縮されるので、補強用リブ38と上下の
硬化樹脂層36.36とが強固に接着する。又、合体時
に余剰となる接着剤は、合わせ面の溝40内に収容され
る。
Then, the joining portion of the cured resin layer 36 and the reinforcing rib 38
An adhesive 42 made of epoxy resin or the like is attached to the tip of the plaster mold, and then the upper and lower halves 22.26 of the plaster mold are closed by aligning the positioning recesses 24 and the protrusions 28 of the mating surfaces.
The cured resin layers 36, 36 are bonded together. At this time, the reinforcing ribs 38 are pressed and compressed by the inner surfaces of the upper and lower cured resin layers 36.36, so that the reinforcing ribs 38 and the upper and lower cured resin layers 36.36 are firmly adhered to each other. Also, excess adhesive during assembly is accommodated in the groove 40 of the mating surfaces.

(ホ)合体物の取り出し工程(第8図)接着剤42の硬
化後、石膏型を破壊して硬化樹脂層36.36の合体物
を取り出し、マスターモデル44を得る。なお、マスタ
ーモデル440合わせ部外面にはみだした接着剤等は、
必要に応じて研摩等により除去する。
(e) Step of taking out the combined product (FIG. 8) After the adhesive 42 has hardened, the plaster mold is destroyed and the combined product of the cured resin layers 36 and 36 is taken out to obtain a master model 44. Please note that any adhesive that protrudes from the outer surface of the master model 440 mating part,
Remove by polishing, etc. if necessary.

このようにして得られたマスターモデル44は、発泡成
形型の鋳造時に常法どおり用いられる。その鋳造を次に
簡単に記す。
The master model 44 thus obtained is used in the usual manner when casting a foam mold. The casting process will be briefly described below.

まず、前記マスターモデルの表面に樹脂皮膜を数mm厚
に形成する。この樹脂皮膜は、マスターモデル形状を反
転した形状からなる。次にこの樹脂 l皮膜をマスター
モデルから外し、砂中に埋めて砂型を作る。そして、そ
の樹脂皮膜を破壊して砂型から除去する。このようにし
て得られた砂型の中空部分に、アルミ等の金属溶湯を流
し込み、冷却固化させることによって発泡成形型を作製
する。
First, a resin film with a thickness of several mm is formed on the surface of the master model. This resin film has a shape that is an inversion of the master model shape. Next, this resin film is removed from the master model and buried in sand to create a sand mold. The resin film is then destroyed and removed from the sand mold. A foam mold is produced by pouring a molten metal such as aluminum into the hollow part of the sand mold obtained in this manner and cooling and solidifying the metal.

(発明の効果) この発明は、発泡成形品を直接モデルとして石膏型を作
製し、その石膏型の型面に硬化樹脂層を積層形成した後
、その硬化樹脂層を合体させてマスターモデルを製造す
るものであるために、木材の切断、接合等からなる熟練
した作業を不要とし、容易かつ短期間にマスターモデル
を製造することが可能となったものである。これにより
マスターモデルが廃棄された場合であっても迅速な対応
が可能であり、緊急時等における対処を容易ならしめる
効果を奏する。
(Effects of the Invention) This invention involves creating a plaster mold using a foam molded product as a direct model, laminating a cured resin layer on the surface of the plaster mold, and then combining the cured resin layers to produce a master model. This eliminates the need for skilled work such as cutting and joining wood, making it possible to manufacture a master model easily and in a short period of time. As a result, even if the master model is discarded, it is possible to respond quickly, and this has the effect of making it easier to deal with emergencies and the like.

又、発泡成形品単品の図面を入手できない場合でも、直
接発泡成形品からマスターモデルの製造を行なうことが
できる効果もある。
Furthermore, even if a drawing of a single foam molded product is not available, a master model can be manufactured directly from the foam molded product.

【図面の簡単な説明】[Brief explanation of drawings]

図面は、この発明一実施例における製造工程を示す断面
図、あるいは部分断面図であり、第1図は含浸硬化樹脂
層の形成工程、第2図乃至第5図は石膏型の作製工程、
第6図は効硬化脂層の積層工程、第7図は硬化樹脂層の
合体工程、第8図は合体物の取り出し工程を示す。 10  発泡成形品、12  含浸硬化樹脂層、22 
 石膏型上半休、26  石膏型下半休、36  硬化
樹脂層、44  マスターモデル 特許出願人   井上エムチーピー株式会社第7図 zb 第8図
The drawings are cross-sectional views or partial cross-sectional views showing the manufacturing process in one embodiment of the present invention, in which Figure 1 shows the process of forming an impregnated hardened resin layer, Figures 2 to 5 show the process of making a plaster mold,
FIG. 6 shows the process of laminating the cured resin layers, FIG. 7 shows the process of combining the cured resin layers, and FIG. 8 shows the process of taking out the combined product. 10 Foam molded product, 12 Impregnated cured resin layer, 22
Upper half of plaster mold, 26 Lower half of plaster mold, 36 Cured resin layer, 44 Master model patent applicant Inoue MCHIP Co., Ltd. Figure 7 zb Figure 8

Claims (1)

【特許請求の範囲】 (イ)発泡成形品表面に含浸硬化樹脂層を形成する工程
、 (ロ)含浸硬化樹脂層が形成された発泡成形品をモデル
として、その形状を転写した型面を有する分割可能な石
膏型を作製する工程、 (ハ)分割した石膏型の型面に硬化樹脂層を積層する工
程、 (ニ)硬化樹脂層を合体させる工程、及び (ホ)その合体物を石膏型から取り出す工程からなる、
発泡成形型作製用マスターモデルの製造方法。
[Claims] (a) A step of forming an impregnated cured resin layer on the surface of the foamed molded product; (b) A mold surface having a shape transferred from the foamed molded product on which the impregnated cured resin layer has been formed as a model. (c) a step of laminating a cured resin layer on the mold surface of the divided plaster mold; (d) a step of combining the cured resin layers; and (e) a step of forming the combined product into a plaster mold. The process consists of taking it out from
A method for manufacturing a master model for making a foam mold.
JP3020686A 1986-02-14 1986-02-14 Manufacture of master model for preparing foam molding tool Granted JPS62187002A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP3020686A JPS62187002A (en) 1986-02-14 1986-02-14 Manufacture of master model for preparing foam molding tool

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP3020686A JPS62187002A (en) 1986-02-14 1986-02-14 Manufacture of master model for preparing foam molding tool

Publications (2)

Publication Number Publication Date
JPS62187002A true JPS62187002A (en) 1987-08-15
JPH0579004B2 JPH0579004B2 (en) 1993-11-01

Family

ID=12297259

Family Applications (1)

Application Number Title Priority Date Filing Date
JP3020686A Granted JPS62187002A (en) 1986-02-14 1986-02-14 Manufacture of master model for preparing foam molding tool

Country Status (1)

Country Link
JP (1) JPS62187002A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4946637A (en) * 1989-01-17 1990-08-07 Masciarelli Jr Victor J Molding method
WO1991011311A1 (en) * 1990-01-24 1991-08-08 Sellers Stephen N Method of making a stained glass article
EP1813407A2 (en) * 2006-01-27 2007-08-01 Martini S.p.A. Sponge production process and plant

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4946637A (en) * 1989-01-17 1990-08-07 Masciarelli Jr Victor J Molding method
WO1991011311A1 (en) * 1990-01-24 1991-08-08 Sellers Stephen N Method of making a stained glass article
US5039468A (en) * 1990-01-24 1991-08-13 Sellers Stephen N Method of making a stained glass article
EP1813407A2 (en) * 2006-01-27 2007-08-01 Martini S.p.A. Sponge production process and plant
EP1813407A3 (en) * 2006-01-27 2010-02-24 Martini S.p.A. Sponge production process and plant

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