Model component and method for manufacturing the same

Abstract

The present invention provides a model component having a gradient change with stable quality and a method for manufacturing the model component. The model component comprises: a first layer formed of a first material of a first color; and a second layer formed so as to cover at least a portion of the first layer and formed of a second material of a second color different from the first color, wherein the second layer is configured to include a first portion where the first layer can be observed and confirmed, and a second portion which is continuous with the first portion and where the first layer cannot be observed and confirmed.

Description

[0001] This application is a divisional application of an application with an application date of October 30, 2019, application number 201911046669.3, and invention name “Model components and method for manufacturing model components”. Technical Field

[0002] The invention relates to a model component and a method for manufacturing the model component. Background Art

[0003] When coloring the parts (also called parts) of assembled models such as so-called plastic models (Japanese: プラモデル, registered trademark), such as the face of a toy, the parts are painted one by one by hand or by spraying using a mask with openings at the colored parts (see Patent Document 1). In addition, it has been proposed to automate the painting using a coloring device equipped with a plurality of printers and conveyors (see Patent Document 2).

[0004] Patent Document 1: Japanese Utility Model Publication No. 3-34226

[0005] Patent Document 2: Japanese Patent Application Laid-Open No. 8-47585 Summary of the invention

[0006] Problem that the invention aims to solve

[0007] However, it takes skill to implement a gradation in which the color becomes darker in a stepwise manner, and it is difficult to stabilize the quality. In addition, when a color device for painting is used, there are problems such as additional equipment investment and large-scale equipment.

[0008] Therefore, an object of the present invention is to provide a model component in which gradual change is performed with stable quality, and a method for manufacturing the same.

[0009] Solutions for solving problems

[0010] The invention of the model component has:

[0011] a first layer formed of a first material of a first color; and

[0012] a second layer formed so as to cover at least a portion of the first layer and made of a second material of a second color different from the first color,

[0013] The second layer is configured to include a first portion in which the first layer can be observed and recognized, and a second portion which is continuous with the first portion and in which the first layer cannot be observed and recognized.

[0014] The invention of the method for manufacturing a model component comprises:

[0015] In the first step, the first material of the first color is used to form the first layer;

[0016] a second step of forming a second layer using a second material of a second color different from the first color so as to cover at least a portion of the first layer; and

[0017] In a third step, a third layer is formed using the second material of the second color so as to cover at least a portion of the surface of the first layer opposite to the surface on which the second layer is formed.

[0018] In the second step, the second layer is formed in a state where the surface on the opposite side of the first layer is supported,

[0019] In the third step, the third layer is formed while the second layer is supported.

[0020] At least one of the second layer and the third layer is formed to include a first portion in which the first layer can be observed and recognized, and a second portion which is continuous with the first portion and in which the first layer cannot be observed and recognized.

[0021] Effects of the Invention

[0022] According to the present invention, it is possible to provide a model component in which a gradual change is performed with stable quality and a method for manufacturing the same. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a flowchart showing an example of a method for manufacturing a model component according to an embodiment of the invention.

[0024] Figure 2 It is a figure for demonstrating the molded object produced by the manufacturing method of the model component corresponding to embodiment of the invention.

[0025] Figure 3 It is a diagram for explaining the structure of a model component corresponding to an embodiment of the invention.

[0026] Figure 4 It is a diagram for explaining the cross-sectional structure of a model component corresponding to an embodiment of the invention. DETAILED DESCRIPTION

[0027] Hereinafter, exemplary embodiments of the invention will be described with reference to the accompanying drawings. In addition, in each figure, the same reference numerals represent the same elements. Moreover, in each figure, the up-down, down-down, left-right, and right-left directions of the paper are set as the up-down, down-down, left-right, and right-left directions of the components (or parts) of the present embodiment, and are used in the description of this specification. In addition, the present invention exemplifies polystyrene as a molding material in the embodiments described below, but is not limited to this, and does not exclude the use of other materials (thermoplastic resins such as polyethylene and ABS, thermosetting resins, metals, etc.).

[0028] First, follow Figure 1 The flowchart of the present invention illustrates a method for manufacturing a model component corresponding to an embodiment of the invention. In S101, primary molding is performed to form a primary molding layer constituting a skeleton portion of the model component. As a molding material (raw material) for the primary molding layer, opaque polystyrene (PS) or reinforced polystyrene (KPS) can be used. Next, in S102, secondary molding is performed to form a secondary molding layer on the surface of the primary molding layer in a manner covering half of the primary molding layer. As a molding material for the secondary molding layer, for example, transparent or translucent general-purpose polystyrene (GPPS) can be used. Next, in S103, tertiary molding is performed to form a tertiary molding layer on the remaining portion of the surface of the primary molding layer in a manner covering the primary molding layer. The secondary molding layer and the tertiary molding layer form the outer surface (outer skin) of the model component, but the degree of color transmittance of the primary molding layer formed on the lower side is different corresponding to the thickness of the secondary molding layer and the thickness of the tertiary molding layer.

[0029] In the above process, the molding material constituting the primary molding layer has an opaque color (e.g., blue, green, other colors such as solid colors, metallic colors, pearlescent colors, etc.) or a transparent (including translucent) color (e.g., blue, green, other colors), while the molding material of the secondary molding layer and the molding material of the tertiary molding layer have transparent or translucent colors. For example, in the case where the model parts constitute the hair of a doll, the secondary molding layer and the tertiary molding layer constituting the surface are transparent white (translucent white), and in contrast, the primary molding layer can be set to a darker blue or darker green, etc. The color of the secondary molding layer and the color of the tertiary molding layer can be the same color system as the color of the primary molding layer, or they can be similar colors or opposite colors to each other. In this embodiment, by forming the primary molding layer and the secondary molding layer and the tertiary molding layer from molding materials of different colors, and using transparent raw materials or translucent raw materials to form the secondary molding layer and the tertiary molding layer, it is possible to express a gradient in a manner that the primary molding layer of a different color located below the secondary molding layer and the tertiary molding layer is seen through.

[0030] Furthermore, as for the material of the molding material of each molding layer, since the primary molding layer, the secondary molding layer, and the tertiary molding layer are combined and integrated with each other, a common material can be used. In the above example, PS, KPS, and GPPS have different properties, but a common material is used as polystyrene. In addition to polystyrene, ABS resin, polyethylene (PE), etc. can also be used in common. Moreover, raw materials of different materials can also be used in some layers.

[0031] The manufacturing method of the model component including the above-mentioned three-stage molding process can be implemented using, for example, a multi-color molding device. In each molding process, a molding mold corresponding to the process is used. Specifically, the molding material is made to flow into the runner groove of the molding mold and the molding space (membrane cavity) used to mold each component to form a molded object, and the molded object is taken out of the molding mold after cooling. For the molded object made by primary molding and secondary molding, the molding mold installed in the next molding process performs secondary molding or tertiary molding respectively. Since the molding method using a multi-color molding device itself is well known, a more detailed description is omitted.

[0032] Furthermore, the above description is about the case where the primary molding layer is molded by performing the molding process once, but the primary molding layer may be divided according to the thickness of the primary molding layer to be molded and the primary molding may be performed twice. In this case, the molding process performed becomes four stages. By molding the primary molding layer twice, it is possible to reduce the depression and deformation during molding, and produce a molded product with a uniform appearance.

[0033] Next, refer to Figure 2 , according to the corresponding embodiment of the present invention Figure 1 The molding method of the present invention describes the molding steps from the primary molding layer to the tertiary molding layer. Figure 2 It is a cross-sectional view of the molding die and the molded object during the molding process. Figure 2 (A) and Figure 2 (B) corresponds to the one-step molding of S101. Figure 2 As shown in (A), the molding mold 201 and the molding mold 202 (a male mold and a female mold, and the distribution of the male mold and the female mold can also be reversed) have a membrane cavity 203 corresponding to the primary molding layer to be molded, so that the molding material flows into the membrane cavity 203 through the main runner and the auxiliary runner not shown in the figure, thereby forming a component.

[0034] Then, if Figure 2As shown in (B), a molded object 204 is produced in a single molding using a molding mold 201 and a molding mold 202. The molded object 204 includes a main runner, an auxiliary runner, and a primary molding layer. The molded object 204 is formed of polystyrene (PS). The main runner is formed in a manner surrounding the periphery of the component, and the component is connected to the main runner via an auxiliary runner, thereby being fixed relative to the main runner. Moreover, the main runner and the auxiliary runner correspond to grooves for allowing the molding material to flow into the membrane cavity 203 in the molding mold 201 and the molding mold 202. In the single molding of S101, the molding material is allowed to flow from the main runner groove of the molding mold 201 and the molding mold 202 into the membrane cavity 203 via the auxiliary runner groove. After the molding material fills all the membrane cavities, the main runner grooves, and the auxiliary runner grooves, the molded object 204 including the primary molding layer can be produced by cooling.

[0035] Next, in the secondary molding at S102 , a secondary molding layer is formed so as to cover the upper side of the primary molding layer. Figure 2 (C) and Figure 2 (D) corresponds to the secondary molding of S102. Figure 2 As shown in (C), a cavity 212 corresponding to the secondary molding layer to be formed in the secondary molding is formed between the molding die 211 and the molding object 204, and the molding material is made to flow into the cavity 212 through the main runner and the sub-runner not shown. Figure 2 As shown in (D), a molded object 213 including a secondary molded layer is formed, and at least a portion of the primary molded layer is covered with general-purpose polystyrene (GPPS). The molded object 213 includes a main runner, a secondary runner, and a secondary molded layer. In this embodiment, GPPS is formed on the upper surface of the primary molded layer via the secondary runner from the main runner, thereby forming a secondary molded layer. At this time, the lower side of the primary molded layer is supported by the molding mold 202, so that the position of the molded object 204 does not change, and the molded object 213 can be accurately formed in a manner that the thickness of the secondary molded layer becomes the desired thickness.

[0036] In the secondary molding of S102, after the molded object 204 is fixed to the inner side of the molding mold 211 and the molding mold 202, the molding material (GPPS) flows from the main runner groove into the membrane cavity 212 via the auxiliary runner groove. After the molding material fills all the membrane cavities 212, the main runner grooves and the auxiliary runner grooves, the molded object 213 can be formed on the upper surface of the molded object 204 by cooling.

[0037] Next, in the tertiary molding in S103 , a tertiary molding layer is formed so as to cover the remaining surface of the primary molding layer. Figure 2 (E) and Figure 2(F) corresponds to the three-stage molding of S103. The molded object 223 is formed by covering the surface of the molded object 204 where the molded object 213 is not formed with the molding material. In the three-stage molding, the molding mold 211 used in the secondary molding is arranged on the lower side, and the molding mold 221 is arranged on the upper side thereof, and the molding mold 221 forms a film cavity 222 between it and the molded object 204. Thus, the position of the molded object 204 formed with the molded object 213 is fixed by the molding mold 211, so that the size of the film cavity 222 can be prevented from changing during the three-stage molding. In this way, after the molded object 204 formed with the molded object 213 is fixed to the molding mold 221 and the inner side of the molding mold 211, the molding material (GPPS) flows from the main runner groove through the auxiliary runner groove into the film cavity 222, and after the molding material fills all the film cavities, the main runner grooves and the auxiliary runner grooves, the molded object 223 can be formed on the surface of the molded object 204 by cooling. As described above, the model component can be molded.

[0038] In the present embodiment, the molding layer covering the primary molding layer is formed in two steps. However, assuming that the molding layer is to be formed in one forming process, the molding 203 is placed in the film cavity of the molding die in a state supported only by the runner. When the molding material is flowed in this state, the position of the molding 203 changes under the action of the pressure of the molding material, thereby changing the size of the film cavities 212 and 222. As a result, the thickness of the secondary molding layer and the thickness of the tertiary molding layer may not be the predetermined thickness. If the thickness changes, the desired color tone cannot be obtained on the appearance of the finished model part, thus affecting the yield rate. In contrast, by forming the molding layer covering the primary molding layer in two steps, the yield rate can be improved.

[0039] Next, refer to Figure 3 Instructions Figure 1 and Figure 2 An example of the structure of a model component manufactured by the manufacturing method. Figure 3 (A) is a diagram showing an example of a model component 300 as a part of hair of a doll toy produced by a molding process corresponding to the present embodiment. The outer surface 303 of the model component 300 is composed of a secondary molding layer and a tertiary molding layer, and a part of the primary molding layer covered by the secondary molding layer and the tertiary molding layer is exposed to the outside as a connection part 301 and a runner 302. In particular, the runner 302 is exposed on the surface of the secondary molding layer and the tertiary molding layer. The connection part 301 and the runner 302 function as a connection member for connecting to other parts.

[0040] Figure 3 (B) is a separation diagram of the model part 300 being separated into a plurality of molding layers. Figure 3(B) shows a case where one molding is performed in two steps. That is, the first molding layer is composed of the first molding layer 311 and the second molding layer 312, the second molding layer is composed of the third molding layer 313, and the third molding layer is composed of the fourth molding layer 314. The first molding layer 311 and the second molding layer 312 form the skeleton part of the model component, and the third molding layer 313 and the fourth molding layer 314 form the outer skin part of the model component. Hereinafter, for the sake of simplicity, the first molding layer 311 and the second molding layer 312 are collectively referred to as the "skeleton part", and the third molding layer 313 and the fourth molding layer 314 are collectively referred to as the "outer skin part". Moreover, in Figure 3 In (B), the surface of the frame portion is configured such that the molding material is filled throughout the frame without gaps, but may be configured in a comb-like or lattice-like manner including gaps between members.

[0041] In this embodiment, the outer skin portion is formed in a manner covering the frame portion, and a concavo-convex portion is formed on the surface of the outer skin portion, and the thickness is adjusted by the concavo-convex portion. The outer skin portion is a molding layer that forms the surface of the model part 200, and has a surface corresponding to the desired shape of the model. The model part 200 is a part of the hair of the doll toy, and thus the hairstyle is expressed by the surface shape of the outer skin portion.

[0042] If the shape of the outer surface of the skeleton part is compared with the shape of the outer surface of the outer skin part, it is constituted to include a part that is similar in shape to each other and a part that is not similar in shape. The part of similar shape keeps the thickness of the outer skin part at a specified value. On the other hand, the part of not similar shape is formed in a manner having a thickness different from that of the part of similar shape, and the color of the skeleton part that can be visually confirmed from the outside through the outer skin part changes correspondingly to the change in thickness. For example, when the outer skin part is formed by a translucent (e.g., transparent white) raw material and the skeleton part is formed by a blue raw material, the blue color of the skeleton part appears to be turbid through the transparent white outer skin part. At this time, since the thickness of the outer skin part is kept constant in the part of similar shape, the degree of turbidity of the color that can be seen through the translucent outer skin part of the skeleton part is constant. However, if the thickness of the outer skin part is further increased, the degree of turbidity becomes stronger, and only the color of the outer skin part will be confirmed in the part where the skeleton part does not exist. Moreover, when the thickness of the outer skin part becomes thinner, the degree of turbidity becomes weaker and the blue color becomes thicker, so by changing the thickness, the shade can be changed. In addition, since the outer shape of the frame portion is formed in a manner that the tip is tapered, the color of the hair can be expressed as gradually changing from turbid blue to white. Moreover, in the present embodiment, the frame portion (color) can be observed and confirmed from the outer skin portion and the frame portion (color) cannot be observed and confirmed because the frame portion is not included are formed continuously, thereby expressing a gradient caused by the change of color. Here, when the outer skin portion is obtained by combining two or more molded layers, at least one molded layer may have this structure.

[0043] Next, a cross-sectional structure of a model component 300 according to the present embodiment will be described. Figure 4 (A) is an example of Figure 3 A cross-sectional view of a portion of the model component 300 of (A) where the thickness of the outer skin portion is maintained at a predetermined value. Figure 4 As shown in the cross-sectional view of (A), the outer skin portion constituting the outer surface of the model component 300 has a thickness D1, and the overall thickness is uniform. For the portion thus constituted, the color of the model component 300 when viewed from the outside remains uniform. On the other hand, Figure 4 (B) is an example of Figure 3 A cross-sectional view of a portion of the model component 300 of (A) where the thickness of the outer skin portion varies. Figure 4As shown in the cross-sectional view of (B), a portion of the outer skin portion constituting the outer surface of the model component 300 has a thickness D1, and other portions have thicknesses D2 and D3, and the thicknesses are such that D1<D2<D3. For the portions constituted in this way, the greater the thickness of the portion, the greater the degree of mixing of the color of the outer skin portion with the color of the frame portion, and the greater the color change when the model component 300 is observed from the outside. For example, in the case where the outer skin portion is formed of a transparent white raw material, the greater the thickness, the greater the degree of white turbidity, the color tone of the frame portion at D2 is lighter than the color tone of the frame portion at D1, and the color tone of the frame portion at D3 is lighter than the color tone of the frame portion at D2.

[0044] By changing the thickness of the outer skin part locally or entirely in this way, the color of the model part 300 can be made different when viewed from the outside. At this time, in the portion where the thickness of the outer skin part continuously increases, the degree of mixing of the color of the outer skin part with the color of the frame part gradually increases, so that the color gradually fades from the portion where the color of the frame part is most visible through to the color of the outer skin part itself, so that the observer can observe a gradient on the surface of the model part 300.

[0045] The appearance of the gradient can be different depending on the way the thickness of the outer skin portion is changed. For example, by making the thickness change abruptly or gently, the way the color changes from a darker color to a lighter color is different, and thus different gradient expressions can be achieved. In addition, the thickness can also be changed in a decreasing direction. Thus, it is also possible to change from a lighter color to a darker color.

[0046] As described above, according to the present embodiment, it is possible to provide a model component to which gradation is applied with stable quality and a method for manufacturing the same.

Claims

1. A model component, the model component having: a first layer formed of a first material of a first color; and a second layer formed so as to cover at least a portion of the first layer and made of a second material of a second color different from the first color, wherein: The second layer is configured to include a first portion corresponding to the at least one portion and capable of observing and confirming the first layer, and a second portion continuous with the first portion and unable to observe and confirm the first layer because it does not cover the first layer, The second layer includes a portion in the first portion that is configured to cover the entire periphery of the first layer. In the first portion, a thickness of the second layer determined between the second layer and the outer peripheral surface of the first layer varies in the circumferential direction, The first layer is connected to a first runner formed of the first material, and the first runner is used as a connecting member between the model component and other model components when the model component is combined with other model components to form a finished product.

2. The model component according to claim 1, wherein: The second layer includes a portion having a different thickness in the first portion.

3. The model component according to claim 1 or 2, characterized in that The transparency of the first color is lower than the transparency of the second color.

4. The model component according to claim 3, characterized in that The second color is semi-transparent.

5. The model component according to claim 3, characterized in that The first color is opaque, and the second color is semi-transparent.

6. The model component according to claim 3, characterized in that The first color is semi-transparent, and the second color is semi-transparent.

7. The model component according to claim 1, characterized in that The first runner used as the connection member is exposed on the surface of the second layer.

8. The model component according to claim 1 or 2, wherein: The first material is polystyrene, and the second material is general-purpose polystyrene.

9. The model component according to claim 1 or 2, wherein: The second layer includes, in the first portion, a portion where the thickness is uniform along the outer periphery of the first layer and a portion where the thickness is non-uniform along the outer periphery of the first layer.

Images