KR101758067B1 - Die and method for manufacturing same - Google Patents

Abstract

And a HIP layer directly bonded to the base material of the die body by HIP (hot isostatic pressurization) treatment. The bending strength and the toughness are excellent and the surface roughness is finished with high accuracy. In addition, A die having a lip portion finished with a sharp edge and having good abrasion resistance and corrosion resistance is provided.
A die for discharging a coating liquid to be supplied to the die flow path 5 from the lip portion 8 is provided at the tip end side of the die flow path 5 formed in the die body 4 and at least the lip portion 8, Is formed by an HIP layer 20 in which an alloy powder 19 having good corrosion resistance and wear resistance is directly diffusion bonded to the base material of the die body 4 by HIP treatment.

Description

[0001] DIE AND METHOD FOR MANUFACTURING SAME [0002]

The present invention relates to a die (coating die or T-die) for applying a gel or liquid coating liquid (coating liquid) to a traveling flexible band-like support, or for discharging a molten resin for forming a resin film from a lip portion, ) And a manufacturing method thereof.

As a conventional die, for example, as a coating die, there is no specific known document such as a patent publication, but a conventionally used coating die has a lip member made of a cemented carbide attached to the tip side of a die channel formed in the die body , High rigidity, abrasion resistance and corrosion resistance can be obtained by the cemented carbide of the lip member, and the accuracy of the tip shape can be improved.

In addition, a resin film produced by an extruder using a T-die is required to have no thickness variation or stripe-like defects, especially for optical applications. Therefore, the inner wall surface of the die flow path which is the flow path of the molten resin is smooth so as to prevent the retention, and in particular, the lip portion to which the molten material is discharged is formed by the sharp edge at the tip end thereof, It is preferable to be formed of a material having high hardness, strength, and abrasion resistance.

Conventionally, it has been proposed to perform hard chromium plating on the inner wall surface of the die passage to reduce friction with molten resin, and to coat the cemented carbide powder having high hardness and high abrasion resistance by spraying, for example, on the lip portion . However, when the hard chromium plating is performed on the wall surface of the die channel and the cemented carbide powder is coated on the lip portion, the adhesion of the hard chromium plating at the tip of the lip portion is poor, It causes a wound. Therefore, if spraying is performed after peeling off the plating layer of the part to be sprayed by the grinding process after the plating treatment, cracks are generated in the joints between the plating part and the sprayed part to easily cause connection failure, There is a concern. When the cemented carbide powder is coated by spraying, the cemented carbide powder mainly composed of WC is melted and ejected. Therefore, when the edge portion is finished by performing grinding and polishing after spraying, peeling or cracking of the powder material It becomes easy to occur.

Thus, a die having a lip portion formed of a cemented carbide and attaching the lip portion to the die body has been conventionally proposed. According to the die having the lip made of cemented carbide attached to the die body, it is possible to obtain high abrasion resistance, corrosion resistance, and strength without causing such peeling and cracking.

However, in the die having the above-mentioned cemented carbide lip member attached to the die body, fine pores remain in the sintered body, and when the crystal is ground, many pinholes are seen and there is a problem in terms of surface roughness. It can not be used in a manufacturing process of a liquid crystal display panel in which application is required. In addition, since the lip members made of cemented carbide are bonded to the die body as a base material by soldering or welding, abrasion and deformation of the joint portions are large due to welding defects, solder defects, It can not be used in a manufacturing process of a liquid crystal display panel in which high precision is required. In addition, there is a possibility that when the molten resin is discharged from the lip portion to form the resin film, an extremely thin and highly accurate resin film can not be produced.

SUMMARY OF THE INVENTION In view of the above circumstances, the present invention has been made to solve the above-mentioned problems, and has an object of providing a Hip layer made of a HIP layer directly bonded to a base material of a die body by HIP (Hot isostatic pressing, abbreviated as Hot Isostatic Pressing) The structure of the lip portion can be densified and the surface roughness can be finished with high precision. In addition, strength of the joint portion is not reduced or occurrence of joining defects is eliminated, and furthermore, the edge portion is finished with high precision sharp edge, and wear resistance and corrosion resistance And it is an object of the present invention to provide a die (a coating die and a T-die) having a lip portion that becomes good and a manufacturing method thereof.

The invention according to claim 1 is characterized in that a lip portion is provided at the tip side of a die passage formed in a die body, and a coating liquid or a coating liquid supplied to the die passage A die for discharging a molten resin from a lip portion is characterized in that at least the lip portion is formed by a HIP layer obtained by diffusion-bonding an alloy powder having good corrosion resistance and wear resistance directly to a base material of a die body by HIP (hot isostatic pressing) .

The invention according to claim 2 is characterized in that in the die according to claim 1, the alloy powder to be subjected to the HIP treatment is composed of a nickel-based alloy or a cobalt-based alloy.

According to a third aspect of the present invention, the base material of the die body is characterized in that it is made of a two-phase stainless steel of austenite / ferrite in the die of the first aspect.

According to a fourth aspect of the present invention, in the die according to the first aspect, a hard chromium plating layer or electroless nickel plating layer is formed on the inner wall surface of the die body forming the die flow paths other than the lip portion.

According to a fifth aspect of the present invention, there is provided a method of manufacturing a die provided with a lip portion at a tip end side of a die passage formed in a die body and discharging a coating solution or a molten resin supplied to the die passage from a lip portion, And an HIP layer formed by directly bonding an alloy powder having good corrosion resistance and wear resistance to the base material of the die body.

According to a sixth aspect of the present invention, in the method of manufacturing a die according to the fifth aspect of the present invention, a capsule made of a die material having recessed portions for alloy powder is formed, and the recessed portion of the die- And an HIP layer formed by direct diffusion bonding of the alloy powder to a die material by carrying out HIP treatment under a high temperature and high pressure by filling the alloy powder having good abrasion resistance into a treatment chamber of a HIP device, The die body is formed by machining the layer, and a die flow path is formed in the die body.

According to a seventh aspect of the present invention, in the method of manufacturing a die according to the sixth aspect, the upper die and the lower die are formed by cutting and removing unnecessary portions of the upper die material and the lower die material, respectively, The upper die and the lower die are abutted against each other so that the die body is formed, and the upper and lower dies are integrally formed with the liner between the abutment surfaces So that a die flow path is formed in the die body.

According to the eighth aspect of the present invention, in the method of manufacturing a die according to the sixth aspect of the invention, the concave portion for the alloy powder is formed in a shape such as three-dimensionally curved or curved, And a die-flow passage of the die is formed.

According to a ninth aspect of the present invention, in the method of manufacturing a die according to the fifth aspect, a hard chrome plating layer or electroless nickel plating layer is formed on the inner wall surface of the die body forming the die flow path other than the lip portion.

According to a tenth aspect of the present invention, in the method of manufacturing a die according to the ninth aspect, in order to perform a hard chromium plating treatment or an electroless nickel plating treatment on the inner surface side of the die material other than the HIP layer as the lip portion, And a hard chromium plating layer or an electroless nickel plating layer is formed on the undercut portion.

The present invention according to claim 11 is the die manufacturing method according to claim 5, wherein the undercut portion includes a part of the HIP layer, and the hard chrome plating layer is formed on the entire inner surface side of the die material subjected to the undercut treatment, Or an electroless nickel plating layer is formed.

According to a twelfth aspect of the present invention, in the method of manufacturing a die according to the eleventh aspect, after forming a hard chromium plating layer or an electroless nickel plating layer over the entire inner surface side of the die material and a part of the HIP layer forming the lip, A hard chromium plating layer or an electroless nickel plating layer on the side of the substrate and an HIP layer forming the lip are cut on one side.

According to the die of the invention according to claim 1, the alloy powder having at least the lip portion 8 having good corrosion resistance and abrasion resistance is subjected to the HIP treatment to form the die The structure of the lip portion is densified by the HIP treatment of the alloy powder and the pores do not remain inside as in the case of the cemented carbide sintered body, The strength of the joint portion is not reduced and no bonding defects are generated, the surface roughness of the lip portion is remarkably improved, the fluidity of the coating liquid becomes very good, and the edge portion is finished with high precision sharp edges And can be used in a manufacturing process of a liquid crystal display panel requiring high-precision coating.

According to the die according to claim 2, when the HIP-treated alloy powder is made of a nickel-based alloy or a cobalt-based alloy, corrosion resistance is further improved.

According to the die according to the invention of claim 3, when the base material of the die body is made of a two-phase stainless steel of austenite / ferrite, since the thermal expansion rate of alloy powder diffusing and bonding to the base material of the die body by HIP processing is close to that, The bending deformation caused by the car is reduced.

According to the die according to the fourth aspect of the present invention, when all of the die channels are to be formed by the HIP layer, the manufacturing cost of the die becomes extremely high. In the die body other than the die, Since the hard chromium plating layer or the electroless nickel plating layer, which is much cheaper than the treatment, is coated, the friction with the coating liquid or the molten resin can be reduced, and the production cost of the die can be reduced.

According to the method for manufacturing a die according to the fifth to seventh aspects of the present invention, at least the lip portion is formed by the HIP layer in which the alloy powder having excellent corrosion resistance and wear resistance is subjected to diffusion bonding directly to the base material of the die body by HIP treatment, , The pores do not remain inside as in the case of the cemented carbide sintered body and pinholes are not generated during grinding or lapping and the strength of the joint portion is reduced or the occurrence of jointing defects The surface roughness of the lip portion is remarkably improved and the fluidity of the coating liquid and the molten resin becomes very good and the edge portion can be finished with high precision sharp edges and the liquid crystal display panel And can be used in a manufacturing process or the like.

According to the method of manufacturing a die of the invention according to claim 8, by forming a HIP layer having a shape that is three-dimensionally curved or curved, it is possible to form a die body from a manifold portion having a shape such as three- It is possible to manufacture a die in which the entire wetted liquid portion of the complex shape inside is formed by the HIP layer.

According to the method of manufacturing a die according to the invention of claim 9, when all of the die channels are to be formed by the HIP layer, the manufacturing cost of the die becomes extremely high. In the die body other than the die, A hard chromium plating layer or an electroless nickel plating layer which is much cheaper than the HIP treatment is coated, so that the friction with the coating liquid or the molten resin can be reduced, and the production cost of the die can be reduced.

According to the method of manufacturing a die of the invention according to claim 10, an undercut treatment of a required amount of cut is performed to perform hard chromium plating or electroless nickel plating on the inner surface of the die material other than the HIP layer as the lip portion , And a hard chromium plating layer or electroless nickel plating layer is formed on the undercut portion, so that a hard chromium plating layer or electroless nickel plating layer of a required thickness can be easily formed.

According to the manufacturing method of the die according to claim 11 and claim 12, the undercut portion includes a part of the HIP layer, and the hard chrome plating layer or the hard chrome plating layer is formed over the entire inner surface side of the die material subjected to the undercut treatment and a part of the HIP layer Since the electroless nickel plating layer is formed, and the hard chromium plating layer or the electroless nickel plating layer on the inner surface side of the die material and the HIP layer forming the lip are cut off on one side, the hard chromium plating layer on the inner surface side of the die material or the electroless nickel The plating layer and the HIP layer forming the lip portion are smoothly finished and can be stably used over a long period of time without causing gaps or peeling phenomena between them.

(A) is a side view showing a coating die according to an embodiment of the present invention, (b) is a front view, (c) is a sectional view taken along the line AA in to be.
Fig. 2 (a) is a sectional view taken along the line CC of Fig. 1 (b), and Fig. 2 (b) is a sectional view taken along line DD of Fig.
Fig. 3 (a) is a sectional view similar to Fig. 2 (a) showing a coating die according to another embodiment, and Fig. 3 (b) is a sectional view showing a coating die according to still another embodiment.
(B-1) is a front view of the upper die material viewed from the mating surface side, (b-2) is a front view of the upper die material, (C-1) is a cross-sectional view in which a core is embedded in an upper die material, (c-2) is a cross-sectional view in which a core material is embedded in an upper die material, ) Is a cross-sectional view of a capsule made by superimposing upper and lower die materials.
Fig. 5 (a) is a cross-sectional view of a state in which an alloy powder is filled in a concave portion of a capsule, Fig. 5 (b) is an explanatory view showing a state in which a capsule is put in a treatment chamber of a HIP apparatus and HIP- Fig.
Fig. 6 (a-1) is a cross-sectional view showing a cutting line for cutting off unnecessary portions of the upper die material subjected to the HIP process, and Fig. 6 (B-1) is a front view showing a cutting line for cutting off unnecessary portions of the HIP-processed upper die material, and (b-2) shows a cutting line for cutting off unnecessary portions of the HIP- (C-1) is a cross-sectional view of the formed upper die from which unnecessary portions are removed, (c-2) is a cross-sectional view of the lower die formed by removing unnecessary portions, and .
Fig. 7 (a-1) is a front view of one die material in which a manifold is formed from a pair of die materials as viewed from the mating surface side, Fig. 7 (B) is a cross-sectional view taken along the line FF of (b-1), (c) is a cross-sectional view in which both die materials are opposed to each other, (E) is a cross-sectional view of a die body made of a pair of die members formed by dismantling a capsule after HIP treatment and machining.
8A is a front view of one die of a die body made of a pair of dies from the abutted surface side, FIG. 8B is a cross-sectional view taken along line AA of FIG. 8A, (C) is a cross-sectional view of a T-die in which a die body is formed by abutting a pair of dies.
Fig. 9 (a) is a cross-sectional view showing a coating die according to an embodiment of the present invention, Fig. 9 (b) is a sectional view taken along line BB of Fig. 9 (a), and Fig.
Figs. 10 (a) to 10 (d) are explanatory views for explaining the HIP process.
Fig. 11 shows a method of manufacturing a coating die according to an embodiment of the present invention, wherein (a-1) is a front view of a die material on one side having a lip portion formed by the HIP layer at the inner wall surface end, (a-2) is a sectional view of the same die material, (b-1) is a front view of an undercut die material, (C-2) is a cross-sectional view thereof. Fig.
Fig. 12 (a) is a cross-sectional explanatory view of a die material showing a grinding processing line for grinding a HIP layer and a hard chromium plated layer to one side, (b-1) 2 is a cross-sectional view thereof, and FIG. 3 (c) is a cross-sectional view of a coating die comprising a die body 4 in which a pair of die members are formed to face each other.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of the present invention will now be described with reference to the drawings. As shown in Fig. 1, a coating die 1 has a die body 4 comprising an upper die 2 and a lower die 3 , And a die channel (5) is provided between the upper and lower dies (2, 3). 1 (a) and 1 (d), the lower die 3 is provided with a coating liquid supply path 6 in which a coating liquid is supplied from the outside by a supply line K as indicated by arrow a, 6, a manifold 7 for expanding in the die width direction is provided after collecting the coating liquid once. These supply paths 6 and the manifold 7 form a part of the die flow path 5 and the lip portions 8 and 8 are provided at the tip end side of the die flow path 5. [

A base portion 9a and two side portions 9b and 9b are formed on the mating faces 2o and 3o of the upper die 2 and the lower die 3 at positions opposed to the rear side of the manifold 7 and at both ends in the width direction, The upper surface 3o of the lower die 3 and the upper surface 3b of the lower die 3 except the portion blocked by the U-shaped liner 9 are attached to the upper surface 3o of the lower die 3, A rib channel portion 10 (see Figs. 1 (a) to 1 (c)) having a thickness t and a width W1 is formed between the lower surface 2o of the die 2 and the rib channel portion 10 The lip inlet 11 of the lip portion 8 positioned at the tip end of the lip portion 8 is discharged.

This coating die 1 is characterized in that at least the lip portion 8 of the die main body 4 is directly diffusion-bonded to the base material of the die main body 4 by HIP (hot isostatic pressing) treatment of an alloy powder having good corrosion resistance and wear resistance And the HIP layer 20 is formed by an HIP layer 20. The HIP layer 20 is shown in an opaque form in each drawing. The upper and lower dies 2 and 3 forming the lip flow path portion 10 in the die flow path 5 formed in the die body 4 And the inner surface side is formed by the HIP layer 20. 3 (a), the HIP layer 20 is formed all over the abutting surfaces 2o and 3o of the upper and lower dies 2 and 3 constituting the die main body 4, and Only the lip portion 8 formed on the tip end side of the die channel 5 is formed by the HIP layer 20 in the coating die 1 shown in Fig.

A method of manufacturing the coating die 1 will be described below with reference to Figs. 4 to 6. Fig. 3 (a), that is, in the case where the HIP layer 20 is formed to extend over the entire area of the abutting surfaces 2o and 3o of the upper and lower dies 2 and 3, (1) will be described.

(A-1) is a cross-sectional view of the upper die material 12, (a-2) is a cross-sectional view of the lower die material 13, (B-2) is a front view of the lower die material 13 viewed from the side of the upper die material 12 facing the upper die material 12. As shown in Fig. The upper die material 12 and the lower die material 13 are made of SUS 329J1 to 4 (a two-phase system of austenite / ferrite) having a coefficient of thermal expansion close to that of the nickel-based alloy powder or the cobalt-based alloy powder used for the alloy powder of the HIP layer 20. [ Stainless steel) is preferable. A rectangular alloy powder recess 14 is formed on the abutting face side of each of the die materials 12 and 13 in a front view and an annular fitting recess 15 is formed in the periphery of the recess 14 And an alloy powder feed port 16 is formed in the upper portion of the concave portion 14 with reference to Fig.

First, as shown in Fig. 4 (c-1) and Fig. 4 (c-2), the plate-shaped inner mold 17, which has been subjected to the mold-releasing treatment of the upper and lower die materials 12, And the upper and lower die materials 12 and 13 are superimposed on each other to weld the dividing line portions shown on the outer periphery of the die materials 12 and 13 to form a capsule 18 are formed. As shown in Fig. 5 (a), the capsules 18 are filled with the alloy powder 19 having good corrosion resistance and wear resistance from the supply port 16 to the recesses 14 in the die materials 12 and 13 , And the side of the supply port 16 is closed by a blocking plate 17A and is degassed and sealed.

A nickel-based alloy powder or a cobalt-based alloy powder is used as the alloy powder 19 having good corrosion resistance and wear resistance. The proportion of constituent elements of the nickel-based alloy powder is preferably 69.75 wt% of nickel, 16.5 wt% of chromium, 3.3 wt% of boron, 4.0 wt% of silicon, 0.65 wt% of carbon, 3.5 wt% of iron, 3.0 wt% of molybdenum and 2.3 wt% . Another preferred nickel-based alloy powder is composed of 58.2 wt% of nickel, 18.0 wt% of chromium, 3.3 wt% of boron, 3.7 wt% of silicon, 0.8 wt% of carbon, 1.5 wt% of iron, 2.5 wt% of molybdenum and 12.0 wt% of tungsten. Another preferred nickel-based alloy powder is composed of 50.05 wt% of nickel, 19.0 wt% of chromium, 3.0 wt% of boron, 3.1 wt% of silicon, 0.85 wt% of carbon, 1.5 wt% of iron, 2.5 wt% of molybdenum and 20.0 wt% of tungsten . On the other hand, preferred as the cobalt-based alloy powder is a powder composed of 45.7 wt% of cobalt, 19.0 wt% of chromium, 15.0 wt% of tungsten, 1.3 wt% of copper, 13.0 wt% of nickel, 3.0 wt% of boron and 3.0 wt% will be.

As shown in the following (b) of Figure 5 a and the capsule 18 to the HIP (Hot such bangap pressure) and accommodated in a chamber 21 of the device, for under 1300 ℃, high temperature and high pressure of 1300Kgf / cm ² g. HIP processing is performed to form the HIP layer 20 in which the alloy powder 19 is directly diffusion bonded to the inner surface side of each of the die materials 12 and 13. The HIP layer 20 is a hard layer having a hardness of HRC 55 to 68 by HIP treatment of nickel-based alloy powder or cobalt-based alloy powder. The capsules 18 having the HIP layers 20 formed on the inner surfaces of the die materials 12 and 13 are disassembled by the HIP process and the die materials 12 and 13 are cut into the die materials 12 and 13, As shown in Fig. 3B, and the central die 17 of each die material 12, 13 is separated.

(A-1) and (a-2) in FIG. 6 cut off unnecessary portions of the upper die material 12 and the lower die material 13, respectively, in which the HIP layer 20 is formed by the above- (B-1), (b-1), and (b-2) of the upper and lower die materials 12 and 13, 2). (c-1) and (c-2) show the upper die 2 and the lower die 3 formed by cutting off unnecessary portions along the cutting lines 22, respectively. In the upper die 2, the coating liquid supply path 6 and the lip flow path portion 10 of the die flow path 5 are formed by drilling, milling, or the like.

Thereafter, the abutting surfaces of the upper die 2 and the lower die 3 are mirror-finished by mirror grinding and the lip inlet 11, which is the leading edge of the lip 8, is finished to 1 탆, The roughness (surface roughness) is finely finished to Ry (maximum height) 0.1 μm. Further, when the lapping is performed, the surface roughness of the abutting surface can be finished up to Ry 0.0 alpha unit.

6D shows a state in which the die body 4 is formed by abutting the upper die 2 and the lower die 3 formed as described above on the abutting surfaces of the die main body 4 and the manifold 7 between the abutting surfaces, 3 (a), which is formed by integrally fastening both upper and lower dies 2 and 3 with bolts or the like in a state where a liner 9 in a substantially U-letter shape is seen in plan view, 1 shows a coating die 1 as shown in Fig.

3 (a), the inside of the die main body 4 extending from the manifold 7 to the lip portion 8 on the tip end side of the lip flow path 10 is made of a corrosion resistant material And the HIP layer 20 that is directly diffusion-bonded to the base material of the die body 4 by the HIP treatment of the alloy powder 19 having good abrasion resistance so that good wear resistance and corrosion resistance are ensured and alloy powder 19 The bending strength is remarkably improved due to the densification of the structure of the lip portion 8 by the HIP treatment of the cemented carbide and the pores do not remain in the interior of the cemented carbide like the sintered product, The surface roughness of the lip portion 8 is remarkably improved and the fluidity of the coating liquid becomes very good and the lip inlet 11 of the lip portion 8 which is an edge portion is formed in a unit of 1 μm Finish with high-precision sharp edges of It is possible, and it is possible to use such a high precision coating process of manufacturing the liquid crystal display panel as required.

Although not shown in the drawing, the HIP process is performed to remove the portion of the die passage 5 extending from the coating liquid supply passage 6 of the die body 4 to the manifold 7, the lip flow passage 10 and the lip portion 8 By forming the HIP layer 20 over the whole area and forming the hard layer with the hardness of HRC 55 to 68, even if a coating liquid having a high abrasion resistance is used, scratches and abrasion are not generated in the liquid- You can use it permanently.

Depending on the coating solution, only the lip portion 8 formed on the tip end side of the die channel 5 may be formed by the HIP layer 20 at all, as in the coating die 1 shown in Fig. 3 (b) No problem.

The manufacturing method of the coating die 1 described with reference to Figs. 4 to 6 is the same as the manufacturing method of the coating die 1 except that the alloy powder 19 is applied to the concave portion 14 for alloy powder of the pair of die materials 12, 13 forming the capsule 18 The die materials 12 and 13 are filled with HIP and processed to form the HIP layer 20 having a linear shape, that is, a rectangular parallelepiped shape, at the required portions of the die materials 12 and 13. However, The HIP layer 20 is formed in a required shape such that it is curved or bent three-dimensionally at a required portion of the HIP layer 20. By forming the HIP layer 20 having a three-dimensionally curved or curved shape as described above, the entire liquid-contact portion extending from the portion of the manifold 7, which is curved or bent three-dimensionally, to the lip portion 8, (20), which is also a feature of the method of the present invention.

7 (a-1) is a front view of one of the pair of die materials 12, 13 from which the manifold is formed, viewed from the side of the die material 13 facing the other die material 13, (B-1) is a front view of the die material 13 seen from the side of the die material 12 facing the die material, and FIG. 2 (b-2) Fig. As shown in (a-1) and (a-2) in the first place, on the mating face side of one die material 12, the upper side has a mountain-like shape and the depth gradually becomes shallower from the mountain- And the concave portion 24 for the alloy powder in the same three-dimensionally curved and curved shape is formed. On the mating surface side of the other die material 13, And a concave portion 25 is formed. Although not shown, alloy powder feed ports are formed in the central upper portions of the concave portions 24 and 25 for the alloy powder of the respective die materials 12 and 13, respectively.

Then, as shown in Fig. 7 (c), in a state in which the abutment surfaces of the pair of die materials 12, 13 are opposed to each other and a plate-shaped hollow mold 27, The upper and lower die materials 12 and 13 are superimposed on each other and the dividing line portion shown on the outer periphery of both die materials 12 and 13 is welded to form a capsule 18 as shown in FIG. The capsules 18 are filled with the alloy powder 19 as in the above-described embodiment in the recesses 24 and 25 in the die materials 12 and 13 from the alloy powder feed port so as to be in a deaerated sealed state.

Thereafter, the capsules 18 are accommodated in the processing chamber 21 of the HIP (isostatic pressurization) apparatus shown in Fig. 5 (b) and HIP processing is performed under high temperature and high pressure, The HIP layer 20 having a curved shape and a curved shape three-dimensionally formed by directly diffusion bonding the alloy powder 19 is formed on the inner surface side of the HIP layer 20. After the capsule 18 having the HIP layer 20 formed on the inner surface side of each of the die materials 12 and 13 by the HIP process is dismantled, the die materials 12 and 13 are separated from each other, (27). 7 (e), one die material 12 is appropriately shaped and the inner surface side of the HIP layer 20 is machined to form the manifold 7 and the lip flow path portion A coating liquid supply path 6 communicating with the manifold 7 is formed and the tip end side of the lip flow path portion 10 is defined as a lip 8. The other die material 13 is appropriately shaped and the inner surface of the HIP layer 20 is also machined if necessary. Thereby, it is possible to manufacture a coating die having a die main body 4 composed of a pair of dies 2, 3 formed with a die flow path 5 curved and bent three-dimensionally not shown.

By forming the HIP layer 20 having the shape of curving or bending three-dimensionally as described above, it is possible to form the HIP layer 20 having the shape of curving or bending three-dimensionally from the portion of the manifold 7 to the lip portion 6 It is possible to manufacture a coating die in which the entire wetted liquid portion having a complex shape inside the coating layer 4 is formed by the HIP layer 20.

Fig. 8 (c) shows a T-die 31, which is an embodiment of a die according to the present invention. Fig. 8 (b) shows another suitable embodiment of the present invention. The T die 31 has a die main body 34 composed of a pair of die members 32 and 33 and a die flow path 35 is formed between both die members 32 and 33, The manifold 37 is provided at the rear end side of the die flow path 35 and the molten resin inflow port 38 is provided at the center of the manifold 37 have. The molten resin introduced from the inlet 38 flows into the lip channel portion 39 while being gathered at the manifold 37 and spread in the die width direction and the lip portions 36, 36, and is discharged from the lip inlet 47 to be extruded in a film form.

The T die 31 is characterized in that each of the lip portions 36 is made of an HIP layer (a heat-isostatic pressed portion) obtained by diffusion-bonding an alloy powder having good corrosion resistance and wear resistance to the die members 32 and 33 40 and the hard chrome plating layer 50 is coated on the inner wall surface of the die members 32, 33 forming the die channels 35 other than the lip portions 36. The HIP layer 40 ) Are shown in an opaque shape in each drawing.

9 shows a coating die 41 which is another embodiment of the die according to the present invention. This coating die 41 has a die body 34 composed of a pair of upper and lower die members 32, 33, A die passage 35 is provided between the die members 32 and 33. The lower die member 33 is provided with a coating liquid supply passage 44 through which a coating liquid is supplied from the outside, A manifold 37 is provided which expands in the die width direction after collecting the coating liquid once. The coating liquid supply path 44 and the manifold 37 form a part of the die flow path 35 and the lip portions 36 and 36 are provided at the tip end side of the die flow path 35.

The abutting surfaces of the die members 32 and 33 are formed at positions opposed to the rear side of the manifold 37 and at both ends in the width direction and in a substantially C shape as seen from the plane of the base 45a and the side portions 45b and 45b The upper surface 33o of the lower die member 33 and the lower surface 32o of the upper die member 32 except for the portion clogged by the upper surface liner 45 are attached with the liner 45 having the thickness t (See Figs. 9 (a) to 9 (c)) having a thickness t and a width W1 are formed between the lip portion 36 and the lip portion 36 located at the tip of the lip portion 39, So that the coating liquid can be discharged from the lip inlet 47 of the discharge port.

This coating die 41 is also used for the HIP layer 40 in which the respective lip portions 6 are alloyed with the die members 32 and 33 by the HIP (hot isostatic pressurizing) treatment with an alloy powder having good corrosion resistance and wear resistance And a hard chromium plating layer 50 is coated on the inner wall surface of the die body 34 forming the die flow path 35 other than the lip portion 36. [ The HIP layer 40 is shown in dotted form in FIGS. 9 (a) to 9 (c).

Next, a method of manufacturing the T die 1 described above and the coating die 41 (FIG. 9 (a)) in the coating die will be described with reference to FIGS. 10 to 11. FIG.

10A to 10D are explanatory diagrams for explaining the HIP process. Fig. 11A-1 is a view showing a die having a HIP layer 40 formed by HIP processing alloy powder at the inner wall surface front end, (A-2) is a cross-sectional view of the die material 42, (b-1) is a front view of the undercut die material 42, (C-1) is a front view in a state in which the hard chromium plating layer 50 is coated on substantially the entire inner wall surface of the die material 42, and (c-2) is a sectional view thereof.

The die materials 42 and 43 are preferably stainless steel SUS329J1-4 (austenitic / ferrite stainless steel duplex) having a thermal expansion coefficient close to that of the nickel-based alloy powder or the cobalt-based alloy powder used for the alloy powder of the HIP layer 40. [

In addition, in order to manufacture a less expensive die, it is possible to further reduce the cost by using the SCM440 material as the material of the die materials 42 and 43 as the base material. Also, by using SCM435 or 440 structural alloy steel as the base material, it is possible to effectively use the hard chrome plating treatment.

As to the method of forming the HIP layer 40 by the HIP treatment of the alloy powder on the inner wall surface end portions of the die materials 42 and 43 as shown in Figs. 11 (a-1) and (a- (A) to 10 (d), first, as shown in Fig. 10 (a), for the alloy powder formed on the tip end portions of the mutually facing surfaces of the two die materials 42 and 43 The two die materials 42 and 43 are brought into contact with each other and the two die materials 42 and 43 are brought into contact with each other while welding the die bodies 62 and 62 having the heat resistant releasable material applied to the concave portions 61 and 61, And the capsules 63 are formed by temporarily fixing the capsules 63. The recesses 61 and 61 for the alloy powder of the die materials 42 and 43 from the powder supply port 64 of the capsule 63 have good corrosion resistance and wear resistance The alloy powder 65 is filled and the powder supply port 64 is closed with a blocking plate 66 and is deaerated and sealed so that the state shown in FIG.

Nickel-based alloy powder or cobalt-based alloy powder is used as the alloy powder having good corrosion resistance and wear resistance. Preferred as the nickel-based alloy powder is a nickel-based alloy powder in which the constituent element ratio is 69.75 wt% of nickel, 16.5 wt% of chromium, 3.3 wt% of boron, 4.0 wt% of silicon, 0.65 wt% of carbon, 3.5 wt% of iron, 3.0 wt% of molybdenum, %. Another preferred nickel-based alloy powder is composed of 58.2 wt% of nickel, 18.0 wt% of chromium, 3.3 wt% of boron, 3.7 wt% of silicon, 0.8 wt% of carbon, 1.5 wt% of iron, 2.5 wt% of molybdenum and 12.0 wt% of tungsten. Another preferred nickel-based alloy powder is composed of 50.05 wt% of nickel, 19.0 wt% of chromium, 3.0 wt% of boron, 3.1 wt% of silicon, 0.85 wt% of carbon, 1.5 wt% of iron, 2.5 wt% of molybdenum and 20.0 wt% of tungsten . On the other hand, preferred as the cobalt-based alloy powder is a powder composed of 45.7 wt% of cobalt, 19.0 wt% of chromium, 15.0 wt% of tungsten, 1.3 wt% of copper, 13.0 wt% of nickel, 3.0 wt% of boron and 3.0 wt% will be.

As then shown to the capsule (63) in (b) of Figure 10 HIP (hot etc. bangap pressure) into the chamber 67 of the device, for example, HIP treatment under 1300 ℃, high temperature and high pressure of 1300Kgf / cm ² The HIP layer 40 in which the alloy powder is diffusion-bonded to the inner wall surface end portions of the respective die materials 42 and 43 is formed as shown in Fig. 10 (c). This HIP layer is a hard layer made of a nickel-based alloy or a cobalt-based alloy having the above-described constituent elements in hardness HRC 57 to 72.

The capsules 63 each having the HIP layer 10 formed on the inner wall surface of each of the die materials 42 and 43 by the HIP treatment are disassembled as shown in Fig. 10 (c) After separating the central mold 62 of the materials 42 and 43, the material is cut and cut to a desired shape so as to be in the state shown in FIG. 10 (d). The portions of the die materials 42 and 43 of the HIP layer 40 become the lip portions 36 of the die members 32 and 33. [ The die materials 42 and 43 shown in Fig. 10 (d) and the die materials 42 and 43 shown in Figs. 11 (a-1) The positional relationship is reversed.

As shown in Figs. 11 (a-1) and 11 (a-2), the die materials 42 and 43 having the HIP layer 40 formed on the inner surface- 11 (b-2) for performing the hard chromium plating treatment, which is the surface treatment, on the inner surface side of the die materials 42, 43 of the die material 42, 43 is performed by cutting . In Fig. 11 (b-2), the undercut portion is indicated by 46. Fig. This undercutting process also performs the portion of the HIP layer 40 that is in contact with the die material 42 and 43 and thus the undercut portion 46 also includes a part of the HIP layer 40 . The amount of undercut (w) in the undercut process can be appropriately set in consideration of the thickness of the plated layer 50 of the hard chrome plating to be performed thereafter.

Hard chromium plating is performed so that the hard chromium plating layer 50 is covered over the entire inner surface side of the die materials 42 and 43 subjected to the undercut treatment and a part of the HIP layer 40 as described above, -1) and (c-2), respectively. The thickness of the plated layer 50 is about 100 탆, which is sufficiently thicker than the final thickness, for example, in that grinding is performed thereafter. In this case, plating preventing means can be suitably applied to the portions of the die materials 42 and 43 and the HIP layer 40 that are not required to be plated. It is also possible to perform plating so that the entirety of the die materials 42 and 43 and the HIP layer 40 are covered with the hard chrome plating layer 50 so that the plating unnecessary portions are removed by grinding or the like in the subsequent step.

After the hard chromium plating layer 50 is thus coated over the whole of the inner surface side of the die materials 42 and 43 and a part of the HIP layer 40 forming the lip portion 36, the inner surfaces of the die materials 42 and 43 And the hard chromium plating layer 50 and the HIP layer 40 are cut to one side. 12 (a), the final grinding line is denoted by G, and the hard chromium plating layer 50 and the HIP layer 40 are cut to the line G, The hard chromium plating layer 50 on the inner surface side of the die materials 42 and 43 and the HIP layer 40 forming the lip portion 36 can be formed on one side as shown in FIG. Thereafter, mirror-surface grinding or mirror-surface processing is performed as necessary. The entire inner surface side of the die materials 42 and 43 and a part of the HIP layer 40 are undercut so that the hard chromium plating layer 50 is bonded to the entire inner surface side of the die materials 42 and 43 and the HIP layer The hard chromium plating layer 50 on the inner surface side of the die materials 42 and 43 and the HIP layer 40 forming the lip portion 36 are cut to be one surface, The hard chromium plating layer or the electroless nickel plating layer 50 on the inner surface side and the HIP layer 40 forming the lip portion 36 are smoothly finished and can be stably used for a long period of time without causing a gap or a peeling phenomenon between them have.

The chromium plating layer 50 on the inner surface side of the die materials 42 and 43 and the HIP layer 40 of the lip portion 36 are finished on one side as described above and then the entire die materials 42 and 43 are cut The upper die member 32 and the lower die member 33 are formed by grinding and mirror-polishing (including buffing), and the lower die member 33 is provided with the coating liquid supply passages 44 and Thereby forming a manifold 37. 12 (c), however, the die body 34 is formed by abutting the upper die member 32 and the lower die member 33, and the die passage 35 is formed in the die body 34 And the lip portions 36 and 36 on the tip side of the die channel 35 are formed.

In order to manufacture the T die 31 and the coating die 41 by the method of the present invention, the die material 42 (Fig. 10) is basically formed as in the embodiment of the manufacturing method of the coating die 41 43 and 43 are subjected to the HIP process and the hard chrome plating process and then the entire die materials 42 and 43 are processed to form the final shape of the coating die 41. The HIP process and the plating process The shape processing may be performed beforehand. In this case, it is necessary to calculate the residual state of the HIP layer 40 on the die materials 42, 43 and the residual state of the hard chrome plating layer 50, and then perform shape processing.

As described above, the shape of the die material including the HIP layer 40 portion before the hard chrome plating process can be obtained by machining or grinding processing from the resin flow port to the leading edge of the outflow port in the case of manufacturing the T die, And a plating process is performed. In this case, machining and grinding before the plating process are performed in consideration of the remaining amount of the hard chromium plating layer (see (b-1) and (b-2) in FIG. 11). After the hard chromium plating, the hard chrome plating layer 50 and the HIP layer 40 are ground on one side as shown in Figs. 12 (b-1) and 12 (b-2) Lapping processing may be performed. Also, in the manifold portion of the three-dimensional shape and the flow portion of the molten resin or the coating liquid, the hard chrome plating processing portion can be mirror-finished by buffing.

According to the T die 31 and the coating die 41 according to the present invention described above, the lip portion 36 of the die body 34 is made of the alloy powder having good corrosion resistance and wear resistance by the HIP treatment, And the HIP layer 40 which is diffusion-bonded to an arbitrary thickness, the structure of the lip portion 8 is densified by the HIP treatment of the alloy powder, and the pores do not remain in the interior of the sintered body made of cemented carbide The surface roughness of the lip portion 36 is remarkably improved and the lip inlet 47 of the lip portion 36 which is the edge portion is made to be the same as that of the lip portion 36, It can be finished with a sharp edge of 1μm unit. In addition, the surface roughness of the lip portion 6 can be finished to Ry of 0.1 占 퐉 at the lip inlet 47, which is the edge portion of the lip portion 36, and further the surface roughness can be finer in the lapping finish.

If all of the die channels 34 of the die body 34 are formed by the HIP layer 40, the cost of manufacturing the die becomes extremely high. However, like the dies 31 and 41 according to the present invention, Only the lip portion 36 is formed by the HIP layer 40 and the inner wall surface of the die body 34 forming the die flow path 35 other than the lip portion 36 is coated with the hard chrome plating which is much cheaper than the HIP treatment, The manufacturing cost of the die can be reduced.

Since hard chromium plating has a small coefficient of friction and is very smooth and hardly adheres to other materials and is a plating having a detergency, friction of the molten resin or the coating liquid is reduced, and even when a molten resin or a coating liquid having strong friction is used, It does not cause scratches or abrasion on the fluid-contacting portion of the flow path 35, and can be used permanently.

The lip portion 36 is formed of the HIP layer 40 obtained by diffusion-bonding the alloy powder to the base material of the die body 34 by an HIP process to an arbitrary thickness. Therefore, compared with the lip portion formed by attaching the cemented carbide material , The bonding strength with the base material is remarkably increased. In addition, since the HIP layer 40 forming the lip portion 36 has a thickness of at least several millimeters to several tens of millimeters, it can be repeatedly used by the maintenance grinding process, and the HIP layer 40 can be repeatedly machined can do. The hard chromium plating layer 50 is inexpensive and can be restored.

The hard chromium plating layer 50 is coated on the inner wall surface of the die body 34 that forms the die flow paths 35 other than the lip portions 36. In place of the hard chromium plating layer 50, A nickel plating layer may be formed on the inner wall surface of the die body 34 for forming the die passage 35 other than the lip portion 36 by the nickel plating treatment. The electroless nickel plating process is a process in which plating is performed without using electricity. Since the thickness of the plating film becomes uniform, if it is immersed in the plating solution, it is suitable to have a complicated shape and dimensional accuracy. The plating layer formed by this electroless nickel plating treatment has good adhesion with the base material, uniform plating film thickness, excellent abrasion resistance equivalent to that of the hard chromium plating layer 50, and excellent corrosion resistance.

One… Coated Die
2… Upper die
3 ... Lower die
4… Die body
5 ... Die euro
6 ... Coating liquid supply path
7 ... Manifold
8… Lip portion
9 ... Liner
10 ... Lip flow portion
11 ... Lip entrance
12, 13 ... Die material
14 ... Concave portion for alloy powder
18 ... capsule
19 ... Alloy powder
20 ... HIP layer
24, 25 ... Concave portion for alloy powder
31 ... Coated Die
32 ... The upper die member
33 ... The lower die member
34 ... Die body
35 ... Die euro
36 ... Lip portion
37 ... Manifold
39 ... Lip flow portion
40 ... HIP layer
41 ... Coated Die
42, 43 ... Die material
50 ... Hard chrome plated layer

Claims (12)

A method of manufacturing a die provided with a lip portion at a tip end side of a die passage formed in a die body and discharging a coating liquid or a molten resin supplied from the lip portion to the die passage is characterized in that the lip portion is made of an alloy The powder is formed by a HIP layer directly bonded to the base material of the die body,
An undercut treatment of a required amount of cut is performed to perform hard chromium plating or electroless nickel plating on the inner surface of the die material other than the HIP layer to which the lip is to be laminated and a hard chromium plating layer or electroless nickel plating Wherein a plating layer is formed on the surface of the die. The capsule according to claim 1, wherein a capsule made of a die material having a concave portion for forming an alloy powder is formed, an alloy powder having good corrosion resistance and wear resistance is filled in the concave portion of the die material alloy powder, The die body is formed by machining the die material and the HIP layer to form a die main body, and the die main body is formed by processing the die material and the HIP layer by forming the HIP layer in which the alloy powder is directly diffusion-bonded to the die material by performing HIP processing under high temperature and high pressure, To form a die flow path in the die. The method as claimed in claim 2, wherein an upper die and a lower die are formed by cutting off the unnecessary portions of the upper die material and the lower die material, respectively, each of which has formed the HIP layer by HIP processing, A die body is formed by abutting the abutting surfaces of the upper die and the lower die formed in this manner and the upper and lower dies are integrally fastened with the liner sandwiched between the abutting surfaces to form a die flow path in the die body ≪ / RTI > The die according to claim 2, wherein the concave portion for forming the alloy powder is formed in a shape such as three-dimensionally curved or curved, and forms a die flow path having a shape such as three-dimensionally curved or curved in the die body ≪ / RTI > The undercut portion according to claim 1, characterized in that the undercut portion includes a part of the HIP layer, and a hard chromium plating layer or electroless nickel plating layer is formed over the entire inner surface side of the die material subjected to the undercut treatment and a part of the HIP layer By weight. The method as claimed in claim 5, wherein a hard chromium plating layer or an electroless nickel plating layer is formed over a part of the inner surface side of the die material and a portion of the HIP layer forming the lip, and then a hard chromium plating layer or electroless nickel plating layer And the HIP layer forming the lip is cut to one side. delete delete delete delete delete delete

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