201023993 六、發明說明： 【發明所屬之技術領域】 本發明係有關於一種快速模具製造方法及快速模具 特別是有關於-種利用高塑性之複合材料的快速模具制翁 及複合材料快速模具。 、程 【先前技術】 一般傳統鈑金模具皆為鋼模，模具鋼胚經取料 工、應力釋除、線切割、放電、研磨加工、拋光到表 理等嚴格道次始得產出模具，開發時程相對較為冗長且造 價高昂’目此’新車測試或維修備品件等具有少量夕樣& 零件產品，業界常選擇快速模具(又稱暫襲具2 = 取代永久性之賴。 ^ 一般快速模具因材料與製程之不同區分為低溶點合金 或鋅合金、鑄鐵模具、樹脂模具、電鱗模具與金屬喷塗模 具..等。上述習知快速模具工法尚無法廣泛應用產業上理 ❿由約如下列所示：低溶點合金為錯，、錫等金屬组成之 合金’價格相對較昂貴且使用時需要加熱設備，鋅合金與 禱鐵亦需要高溫溶解爐溶鍊成铸胚，低溶點合金、辞合金 與鑄鐵應用時皆須完成鑄胚’然後將鑄胚再加工出模面始 成模具；够照圖1所㈣之先前技術之樹脂模具剖視 圖。樹知模具10為使用樹脂、硬化劑與填充物混合後灌注 而成形模仁，對於大型鈑金件之模具而言，全部應用樹脂 材料的成本非常高，造成模具成本降低有限。 201023993 1 因此’習知鈑金沖壓快速模具（如低熔點合金或鋅合 '金、鑄鐵模具、樹脂模具、電鱗模具與金屬喷塗模具..等) 相對地較無法完全針對少量多樣大型鈑金件提供快速、經 •濟及有效率之市場需求，㈣應用上仍有許多改善的空間。 【發明内容】 本發明欲解決的問題係提供—種應料造領域所使用 之砂模製成快速模具之大部分面積之主體部 ，再於砂模之 至少一表面上灌注成型一樹脂硬化層而形成複合材料快速 模具的製造方法及複合材料快速模具。 本發明解決上述製程問題之技術手段係提供一種複合 材料快速模具製造方法，步驟包含：成型一砂模主體該 ^模主體具有-第—表面’該第—表面造型係粗略對應於 工件原型表面造型；製作一樹脂模具框件，該樹脂模具 忙件之一谷置空間内具有至少一定位支撐件；將該工件原 型叹置於該定位支撐件上；組合並定位該砂模主體於該樹 ❹脂模具框件中，該砂模主體之該第一表面與該工件原型表 面相對並保持一間隙；灌注一樹脂混合液於該樹脂模具框 ^之該容置空間中，以於該第一表面上形成一樹脂混合材 料層，以及取出該樹脂混合液硬化結合於該砂模主體所形 成之該複合材料快速模具。 本發明解決上述產品問題之技術手段係提供一種複合 材料快速模具，包含：一砂模主體，係具有一第一表面； 以及一樹脂混合材料層，係成型於該第一表面上，該樹脂 201023993 混合材料層形成一工作表面。 树明讀祕在於，树明糾—種賦的樹脂與 砂模為主要成分之複合材料模具及其製程，樹脂材料 ，製高複雜表面品質佳模具表面，樹脂結構之内部充填耐高 -溫南強度鑄造用砂模材料，型妙價格低廉且經高溫燒結後 強度佳，樹脂與砂模結合之複合材結構應用於大型複雜曲 面產品之簡易模具製造具有縮短時程、精度佳、品質好又 經濟的優勢。 β【實施方式】 茲配合圖式將本發明較佳實施例詳細說明如下。 首先請參照圖2所緣示之本發明複合材料快速模具製 造方法實施例之流程圖以及圖3Α至圖3Ε所㈣圖2之結 構剖面示意圖。本實施例中，其製造方法包含： (步驟S100)成型一砂模主體2〇，該砂模主體2〇具有 第表面22，較佳地，該第一表面22的造型係約略對 應於一工件原型30表面造型（如圖3Α所示）。上述砂模主 體20係以一鑄砂混合水玻璃(Ν_〇3)所組成之一石夕砂水 玻璃混合物經燒結製程而製成。其應用之燒結製程係將該 矽砂水玻璃混合物導入一模箱中，並通入二氧化碳(c〇2) 氣體以形成濕態砂模（硬化成濕態砂模的時間隨模具大小 而有所不同，般約5〜10分鐘，但不以此為限），再將濕 態砂模置入燒結壚中，以最高燒結溫度1〇5〇〇c燒結至少2 小時為之。而上述矽砂水玻璃混合物之該鑄砂顆粒大小為 5 201023993 “ 22 S至60 S，該水玻璃之重量比率為鑄砂之1 %至7 %。 (步驟S110)製作一樹脂模具框件40，該樹脂模具框件 40具有一容置空間41及一蓋板42,該容置空間41内具有 • 至少一定位支撐件43，該定位支撐件43可安裝於該容置 • 空間41之底面或侧壁上（如圖3B所示）。 (步驟S120)將該工件原型30設置於該定位支撐件43 上，且其欲提供複合材料快速模具60複製之工作面係朝上 (如圖3B所示）。 (步驟S130)組合並定位該砂模主體20於該樹脂模具框 件40中，並將該樹脂模具框件40閤上蓋板42，該砂模主 體20之該第一表面22與該工件原型30表面相對並保持一 間隙44，此間隙44即決定覆蓋於該第一表面22上的樹脂 材料的厚度。若覆蓋該砂模主體20不限於該第一表面22， 也欲包含該砂模主體20的其他表面，如侧面或頂面，則須 在定位該砂模主體20於該樹脂模具框件40時，預留該砂 ® 模主體20表面與該樹脂模具框件40容置空間41壁面之間 的距離（如圖3C所示）。 (步驟S140)灌注一樹脂混合液50於該樹脂模具框件 40之該容置空間41中，以於該第一表面22上形成一樹脂 混合材料層51。為使該樹脂混合液50在充填過程中不致 產生氣泡，本步驟在一抽真空製程中進行為佳。而該抽真 空製程，係可在該樹脂模具框件40之該容置空間41中配 置抽真空設備70，以使該樹脂模具框件40形成一真空箱 6 201023993 (如圖3D所示），該真空箱内之真空壓力係低於大氣壓力2 ^ Kg/cm2以上時，始進行灌注該樹脂混合液5〇作業。上述 該樹脂混合液50係包含100%重量之樹脂與300%至500% 重量添加物混合後，再添加5〇%至1〇〇%重量之硬化劑而形 .成。上述該重量添加物可為鐵粉、鋁粉、破璃纖維、陶瓷 粉或其他強化結構之填入物。 (步驟S150)取出該樹脂混合液5〇硬化後結合於該砂模 ❷主體所形成之該複合材料快速模具6〇(如圖3E所示），樹脂 混合液50硬化的時間隨模具大小而有所不同，一般約為 5〜40分鐘，但不以此為限。 上述之工件原型30表面係為一飯件零件的外表面 時，其所製成之該複合材料快速模具60可為一動模模具或 為一定模模具；而上述工件原型30表面為一鈑件零件的内 面時’其製成之該複合材料快速模具60亦可為一動模模具 或可為一定模模具。 _ 另外，為利於該複合材料快速模具60成形後順利脫 模，在該工件原型30設置於樹脂模具框件内之定位支撐件 上的時候或之前，更包含一喷灑離型劑之步驟，以對該工 件原型30表面或樹脂模具框件40内表面進行喷灑離型劑。 請參照圖4所繪示本發明複合材料快速模具埋設支撐 架體實施例之剖示圖。其為使該砂模主體20在燒結之後獲 得更佳的抗拉強度，係可在該矽砂水玻璃混合物中更埋設 至少一支撐架體21。當然，若製成之複合材料快速模具60 201023993 •屬於大型模具時’所埋設之該支撐架體21之一端可向外突 - 伸，形成一固定栓211的固持結構，以利夾持搬運。 再請參照圖5所繪示本發明複合材料快速模具之表面 . 形成粗糙面實施例之剖示圖。本實施例中，該砂模主體20 - 與該樹脂混合材料層51之結合面具有至少一刻痕圖案之 粗縫面S造型’以提高該樹脂混合材料層之結合強度。 請參照圖3E所示，本發明所提供之複合材料快速模具 實施例’其複合材料快速模具60包括：一砂模主體20係 具有一第一表面22;以及一樹脂混合材料層51係成型於 該第一表面22上，該樹脂混合材料層51形成一工作表面 61。該樹脂混合材料層51係包含1〇〇%重量之樹脂與300% 至500%重量之添加物混合後’再添加5〇%至ι〇〇%重量之 硬化劑而形成，其中’該重量添加物可為鐵粉、鋁粉、玻 璃纖維或陶瓷粉等可強化結構之添加物。該複合材料快速 模具60可為一動模或一定模，其中該砂模主體2〇與該樹 Q 脂混合材料層51之結合面具有至少一刻痕圖案之粗糙面S 造型，以提高該樹脂混合材料層51之結合強度。且該樹脂 混合材料層51更包覆於該砂模主體2〇該第一表面22之外 的其他表面。 本發明提供一種新式的樹脂與砂模為主要成分之複合 材料快速模具及其製程，樹脂材料可複製複雜度高且表面 品質佳之模具表面，樹脂結構之内部充填耐高溫、高強度 之鑄造用砂模材料，型砂價格低廉且經高溫燒結後強度 佳，樹脂與砂模結合之複合材結構應用於大型複雜曲面產 8 201023993 品之快速模造具有縮料程、精度佳。 ::勢。本發明特別適用於新車開發或維修二:又經濟 鈑金模具之少量多樣之應用上，本發明件之大型 快速模具工法，達到快速、經濟、有效車 取代現有 ::合應用於汽車大型鈑金件:發::;之== 〇以上，縮短開發時程50%以上。與 目、 約:節省8。%以上之樹脂材料成本。樹脂表面層曰複製= =面品質好，成形速度快。與鋅合金、低熔點合金與鱗 鐵I比較’不需加熱溶解設備且不必後加工成形模面， 具有施工簡S且時賴短等聽。應用耐高溫之多孔性砂 模與樹脂結合成形性佳，對於大型鈑金件模具具有吸震效 果，模具壽命較一般全樹脂模具長且價格低廉。且本發明 應用範圍廣泛，幾乎可同時應用於汽車、航太、醫療與工 具機等產業，產品上可應用於塑膠模具與射蠟模具等場合。 综上所述，乃僅記載本發明為呈現解決問題所採用的 ❹技術手段之實施方式或實施例而已，並非用來限定本發明 專利實施之範圍。即凡與本發明專利申請範圍文義相符， 或依本發明專利範圍所做的均等變化與修飾，皆為本發明 專利範圍所涵蓋。 【圖式簡單說明】 圖1繪示先前技術之樹脂模具剖視圖； 圖2繪示本發明複合材料快速模具製造方法實施例之流 程圖； 圖3A至圖3E繪示圖2之結構剖面示意圖； 201023993 圖4繪示本發明複合材料快速模具埋設支撐架體實施例 之剖示圖；以及 圖5繪示本發明複合材料快速模具之表面形成粗糙面實 施例之剖示圖。 【主要元件符號說明】201023993 VI. Description of the Invention: [Technical Field] The present invention relates to a rapid mold manufacturing method and a rapid mold, and more particularly to a rapid mold making and composite rapid mold using a high plasticity composite material. , [previous technology] The traditional traditional sheet metal molds are steel molds, mold steel embryos through the material extraction, stress release, wire cutting, discharge, grinding, polishing to the surface of the string, such as the strict pass to produce mold, development The time course is relatively long and costly. 'This is a new car test or maintenance spare parts, etc. There are a few small sample & parts products, the industry often chooses the rapid mold (also known as the temporary attack 2 = replace the permanent. ^ General fast Molds are distinguished by low melting point alloys or zinc alloys, cast iron molds, resin molds, electric scale molds and metal spray molds due to differences in materials and processes. The above-mentioned fast mold methods are not widely used in industry. It is as follows: the alloy with low melting point is wrong, and the alloy composed of tin and other metals is relatively expensive and requires heating equipment when used. Zinc alloy and prayer iron also need high temperature dissolution furnace to form a cast embryo, low solubility. When casting alloys, alloys and cast irons, it is necessary to complete the casting of the embryos and then recast the casting blanks into the mold surface into a mold; a cross-sectional view of the resin mold of the prior art according to Fig. 1 (4). The mold 10 is formed by mixing a resin, a hardener, and a filler, and then molding the mold core. For a mold of a large sheet metal part, the cost of applying the resin material is very high, resulting in a limited reduction in mold cost. 201023993 1 Therefore, 'the knowledge of gold Stamping rapid molds (such as low melting point alloys or zinc alloy 'gold, cast iron molds, resin molds, scale molds and metal spray molds, etc.) are relatively incapable of providing fast, economical and economical solutions for a small number of large sheet metal parts. There is still a lot of room for improvement in the application of the market demand. (4) The problem to be solved by the present invention is to provide a body part of a large area of a rapid mold which is used in the field of material preparation. And forming a composite material rapid hard mold manufacturing method and a composite material rapid mold by injecting a resin hardened layer on at least one surface of the sand mold. The technical means for solving the above process problem provides a composite material rapid mold manufacturing method, The step includes: molding a sand mold body, the mold body has a - surface - the first surface The model corresponds roughly to the surface shape of the workpiece prototype; a resin mold frame member is formed, and at least one positioning support member is disposed in the valley space of the resin mold busy member; the workpiece prototype is placed on the positioning support member; Positioning the sand mold body in the tree mold frame member, the first surface of the sand mold body is opposite to the workpiece prototype surface and maintaining a gap; and the resin mixture is filled in the resin mold frame In the space, a resin mixed material layer is formed on the first surface, and the composite material quick-release mold formed by hardening and bonding the resin mixture to the sand mold body is taken out. The technical means for solving the above product problem is provided by the present invention. A composite rapid mold comprising: a sand mold body having a first surface; and a resin mixed material layer formed on the first surface, the resin 201023993 mixed material layer forming a working surface. Shuming’s secret lies in the fact that Shu Mingzheng is a composite mold with a resin and sand mold as the main component and its process, resin material, high complex surface quality, good mold surface, internal filling of resin structure, high-temperature resistance Sand mold material for strength casting, low cost and good strength after high temperature sintering. Composite structure of resin and sand mold is applied to simple mold manufacturing of large complex curved surface products with shortened time history, high precision, good quality and economy. The advantages. β [Embodiment] A preferred embodiment of the present invention will be described in detail below with reference to the drawings. First, referring to Fig. 2, a flow chart of an embodiment of a composite rapid mold manufacturing method of the present invention and a schematic cross-sectional view of Fig. 3 to Fig. 3 (4) Fig. 2 are shown. In this embodiment, the manufacturing method comprises: (Step S100) molding a sand mold body 2, the sand mold body 2 has a first surface 22, preferably, the shape of the first surface 22 corresponds to a workpiece Prototype 30 surface modeling (as shown in Figure 3). The sand mold body 20 is made by a sintering process of a mixture of a sand-mixed water glass (Ν_〇3). The sintering process of the application is to introduce the strontium water glass mixture into a mold box and pass carbon dioxide (c〇2) gas to form a wet sand mold (the time of hardening into a wet sand mold varies with the size of the mold) Different, generally about 5 to 10 minutes, but not limited to this, the wet sand mold is placed in a sintered crucible and sintered at a maximum sintering temperature of 1 〇 5 〇〇 c for at least 2 hours. The size of the foundry sand of the above-mentioned enamel water glass mixture is 5 201023993 "22 S to 60 S, and the weight ratio of the water glass is 1% to 7% of the foundry sand. (Step S110) A resin mold frame member 40 is produced. The resin mold frame member 40 has an accommodating space 41 and a cover plate 42. The accommodating space 41 has at least one positioning support member 43. The positioning support member 43 can be mounted on the bottom surface of the accommodating space 41. Or on the side wall (as shown in Fig. 3B). (Step S120) The workpiece prototype 30 is placed on the positioning support member 43, and the working surface of the composite material rapid mold 60 is intended to be copied upward (Fig. 3B). (Step S130) Combine and position the sand mold body 20 in the resin mold frame member 40, and close the resin mold frame member 40 to the cover plate 42, the first surface 22 of the sand mold body 20. Opposite the surface of the workpiece prototype 30 and maintaining a gap 44, the gap 44 determines the thickness of the resin material covering the first surface 22. If the sand mold body 20 is not limited to the first surface 22, it is also intended to be included. Other surfaces of the sand mold body 20, such as the side or top surface, must be When the sand mold main body 20 is placed on the resin mold frame member 40, the distance between the surface of the sand mold main body 20 and the wall surface of the resin mold frame member 40 accommodating space 41 is reserved (as shown in Fig. 3C). A resin mixed liquid 50 is poured into the accommodating space 41 of the resin mold frame member 40 to form a resin mixed material layer 51 on the first surface 22. In order to prevent the resin mixed liquid 50 from filling during the filling process The bubble is generated, and the step is preferably performed in a vacuum process, and the vacuuming process is configured to dispose a vacuuming device 70 in the accommodating space 41 of the resin mold frame member 40 to make the resin mold frame member. 40 is formed into a vacuum box 6 201023993 (shown in FIG. 3D), and when the vacuum pressure in the vacuum chamber is less than 2 ^ Kg/cm 2 at atmospheric pressure, the resin mixture is poured into the resin. The liquid 50 is formed by mixing 100% by weight of the resin with 300% to 500% by weight of the additive, and then adding 5 to 1% by weight of a hardening agent. The weight additive may be iron powder. Filling of aluminum powder, glass fiber, ceramic powder or other reinforcing structures (Step S150) taking out the resin mixture liquid 5 〇 hardened and bonding to the composite material rapid mold 6〇 formed by the sand mold body (as shown in FIG. 3E), and the resin mixture 50 hardens with the mold size. However, the difference is generally about 5 to 40 minutes, but not limited thereto. When the surface of the workpiece prototype 30 is the outer surface of a rice part, the composite rapid mold 60 can be When the surface of the workpiece prototype 30 is the inner surface of a workpiece part, the composite rapid mold 60 may be a movable mold or a mold. _ In addition, in order to facilitate the smooth demolding of the composite rapid mold 60 after forming, the step of spraying the release agent is further included before or before the workpiece prototype 30 is disposed on the positioning support member in the resin mold frame member. The release agent is sprayed on the surface of the workpiece prototype 30 or the inner surface of the resin mold frame member 40. Referring to Figure 4, a cross-sectional view of an embodiment of the composite rapid mold embedding support frame of the present invention is illustrated. In order to obtain a better tensile strength of the sand mold body 20 after sintering, at least one support frame 21 may be further embedded in the sand water glass mixture. Of course, if the composite material rapid mold 60 201023993 is manufactured, the one end of the support frame body 21 which is embedded in the large mold can be outwardly extended to form a holding structure of the fixing bolt 211 for gripping and carrying. Referring again to Figure 5, the surface of the composite rapid mold of the present invention is shown. A cross-sectional view of a rough surface embodiment is shown. In the present embodiment, the joint surface of the sand mold main body 20 - and the resin mixed material layer 51 has a rough surface S shape of at least one score pattern to improve the bonding strength of the resin mixed material layer. Referring to FIG. 3E, the composite rapid mold embodiment of the present invention has a composite rapid mold 60 comprising: a sand mold body 20 having a first surface 22; and a resin mixed material layer 51 formed on the same. On the first surface 22, the resin mixed material layer 51 forms a working surface 61. The resin mixed material layer 51 is formed by mixing 1% by weight of a resin with 300% to 500% by weight of an additive, and then adding a 5% by weight to ι% by weight of a hardener, wherein the weight is added The material may be an additive of a reinforced structure such as iron powder, aluminum powder, glass fiber or ceramic powder. The composite rapid mold 60 may be a movable mold or a mold, wherein the joint surface of the sand mold main body 2 and the tree Q fat mixed material layer 51 has a rough surface S shape of at least one score pattern to improve the resin mixed material. The bonding strength of layer 51. Further, the resin mixed material layer 51 is further coated on the surface of the sand mold main body 2 other than the first surface 22. The invention provides a new type of rapid mold and a process for preparing a composite material with a resin and a sand mold as main components, the resin material can replicate the surface of the mold with high complexity and good surface quality, and the interior of the resin structure is filled with high temperature and high strength foundry sand. Mold material, sand is cheap and has good strength after high temperature sintering. The composite structure of resin and sand mold is applied to large complex curved surface production. 201023993 The rapid mold making has the advantages of shrinkage and precision. :: Potential. The invention is particularly suitable for the development or maintenance of a new car: in the application of a small amount of various economical gold molds, the large-scale rapid mold method of the invention achieves the rapid, economical and effective replacement of the existing:: for the large-scale sheet metal parts of the automobile: Send::; == 〇 above, shorten the development time by more than 50%. With the purpose, about: save 8. More than % resin material cost. Resin surface layer 曰 replication = = good surface quality, forming speed. Compared with zinc alloy, low melting point alloy and scale I, 'there is no need to heat the dissolving equipment and it is not necessary to post-form the forming surface, and it has a simple construction and a short time. The application of the high-temperature resistant porous sand mold and the resin is excellent in formability, and has a shock absorbing effect on the large-scale sheet metal mold, and the mold life is longer than that of the general all-resin mold and the price is low. The invention has wide application range and can be applied to industries such as automobile, aerospace, medical and tooling machines at the same time, and can be applied to plastic molds and wax molds. In the above, it is merely described that the present invention is an embodiment or an embodiment of the technical means employed to solve the problem, and is not intended to limit the scope of the invention. That is, the equivalent changes and modifications made in accordance with the scope of the patent application of the present invention or the scope of the invention are covered by the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view showing a prior art resin mold; FIG. 2 is a flow chart showing an embodiment of a composite rapid mold manufacturing method according to the present invention; FIG. 3A to FIG. 3E are schematic cross-sectional views showing the structure of FIG. 4 is a cross-sectional view showing an embodiment of the composite material rapid mold embedding support frame of the present invention; and FIG. 5 is a cross-sectional view showing an embodiment of the surface of the composite rapid mold of the present invention. [Main component symbol description]
10 樹脂材料模具 20 砂模主體 21 支撐架體 211 固定栓 22 第一表面 30 工件原型 40 樹脂模具框件 41 容置空間 42 蓋板 43 定位支樓件 44 間隙 50 樹脂混合液 51 樹脂混合材料層 60 複合材料快速模具 61 工作表面 70 抽真空設備 S 粗链面10 Resin material mold 20 Sand mold main body 21 Support frame body 211 Fixing bolt 22 First surface 30 Workpiece prototype 40 Resin mold frame member 41 accommodating space 42 Cover plate 43 Positioning branch member 44 Gap 50 Resin mixture 51 Resin mixed material layer 60 composite rapid mold 61 working surface 70 vacuuming equipment S thick chain surface