Method for manufacturing a shaped article

Abstract

The present application provides a method for manufacturing a molded product capable of reducing the possibility of a recycled material becoming a vortex shape. The method for manufacturing a molded product includes: a first step of jetting a modeling material containing a thermoplastic resin to model a modeled body and forming a first molded product by cutting the modeled body using a first rotary tool; a second step of cutting the first molded product using a second rotary tool to generate a recycled material; and a third step of jetting the plasticized recycled material to form a second molded product. In the second step, the first molded product is cut under at least one condition of a condition in which the moving speed of the second rotary tool is faster than the moving speed of the first rotary tool in the first step and a condition in which the rotating speed of the second rotary tool is slower than the rotating speed of the first rotary tool in the first step.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a forming mold. Background Technology

[0002] A modeling device is known that shapes a three-dimensional object by spraying a plasticized material toward a stage and hardening it.

[0003] For example, Patent Document 1 describes a shaping device that shapes a recycled material by cutting a first molded product, plasticizes the recycled material in a plasticizing section, and uses the plasticized recycled material to shape a second molded product.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2022-10642 Summary of the Invention

[0005] However, when recycled materials are produced by cutting, they sometimes form a vortex shape. When the recycled materials form a vortex shape, they interfere with each other, resulting in a bridging phenomenon that prevents the supply of new recycled materials to the plasticizing section, thus making it impossible to stably plasticize the recycled materials.

[0006] One method for manufacturing the forming mold according to the present invention includes:

[0007] In the first step, a molding material containing thermoplastic resin is sprayed out to shape the molding body, and the molding body is cut by using a first rotating tool to form a first molded product.

[0008] The second step involves using a second rotating tool to cut the first molded article, thereby generating reusable material.

[0009] The third step involves spraying out the plasticized recycled material to form the second molded article.

[0010] In the second step, the first molded article is cut under at least one of the following conditions: the moving speed of the second rotating tool is faster than the moving speed of the first rotating tool in the first step, and the rotating speed of the second rotating tool is slower than the rotating speed of the first rotating tool in the first step. Attached Figure Description

[0011] Figure 1 This is a functional block diagram of the model regeneration system involved in this embodiment.

[0012] Figure 2A perspective view of the three-dimensional modeling device of the modeling product recycling system according to this embodiment is shown schematically.

[0013] Figure 3 This is a cross-sectional view of the ejection unit of the model regeneration system according to this embodiment, for illustrative purposes only.

[0014] Figure 4 A perspective view of the flat spiral component of the model recycling system according to this embodiment is shown schematically.

[0015] Figure 5 A top view of the barrel of the model recycling system according to this embodiment is shown schematically.

[0016] Figure 6 This is a cross-sectional view schematically showing the manufacturing process of a model in the three-dimensional modeling apparatus of the model regeneration system according to this embodiment.

[0017] Figure 7 A side view of the injection molding apparatus of the model recycling system according to this embodiment is shown schematically.

[0018] Figure 8 This is a cross-sectional view of the injection molding apparatus of the model recycling system according to this embodiment, for illustrative purposes only.

[0019] Figure 9 An exploded perspective view of the forming mold of the modeling recycling system according to this embodiment is shown schematically.

[0020] Figure 10 A perspective view illustrating the cutting device of the model recycling system according to this embodiment.

[0021] Figure 11 This diagram illustrates the cutting of a molded object performed by a rotating tool of the molded object regeneration system according to this embodiment.

[0022] Figure 12 A bottom view of the rotating tool of the model regeneration system according to this embodiment is shown schematically.

[0023] Figure 13 A side view of the rotating tool of the model regeneration system according to this embodiment is shown schematically.

[0024] Figure 14 This is a flowchart used to explain the manufacturing method of the shaped article according to this embodiment.

[0025] Figure 15 This is a three-dimensional diagram used to illustrate the experimental example.

[0026] Figure 16 This is a side view used to illustrate the experimental example.

[0027] Figure 17 A photograph showing the appearance of the rotating tool T used in the experimental example.

[0028] Figure 18 A table representing the cutting conditions in the experimental examples.

[0029] Figure 19 A table representing the cutting conditions in the experimental examples.

[0030] Figure 20 This is a photograph of the cutting chips from the experimental example.

[0031] Figure 21 This is a photograph of the cutting chips from the experimental example. Detailed Implementation

[0032] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Furthermore, the embodiments described below are not intended to unduly limit the scope of the present invention as described in the technical solutions. Additionally, not all structures described below are necessarily essential structural elements of the present invention.

[0033] 1. Artwork Recycling System

[0034] 1.1. Overall Structure

[0035] First, the model recycling system according to this embodiment will be described with reference to the accompanying drawings. Figure 1 This is a functional block diagram of the model regeneration system 100 involved in this embodiment.

[0036] like Figure 1 As shown, the model recycling system 100 includes, for example, a three-dimensional modeling device 200, an injection molding device 300, and a cutting device 400.

[0037] The three-dimensional modeling apparatus 200 shapes a first molded article according to the modeling material. The first molded article is, for example, used as at least a portion of the molding die in the injection molding apparatus 300. Figure 1 The arrow markings indicate the process of the molding materials that make up the molded product.

[0038] The injection molding apparatus 300 uses the first molded article as a molding die to perform injection molding. Through repeated use, the first molded article deteriorates. The deteriorated first molded article is then removed from the injection molding apparatus 300.

[0039] The cutting device 400 cuts the first molded article 10 that has been removed from the injection molding device 300. When the first molded article 10 is cut, cutting chips are generated.

[0040] The three-dimensional modeling apparatus 200 plasticizes and ejects the generated cutting chips as reusable material, thereby shaping a second molded article. The second molded article is used, for example, in at least a portion of the molding die of the injection molding apparatus 300.

[0041] By employing the above methods, the molded product recycling system 100 is able to recycle molded products. The following sections will describe each device in turn.

[0042] 1.2. Three-dimensional modeling device

[0043] Figure 2 A perspective view of the three-dimensional modeling device 200 of the modeling reproduction system 100 is shown schematically. Additionally, in Figure 2 In the diagram, the X-axis, Y-axis, and Z-axis are shown as three mutually orthogonal axes. The X-axis and Y-axis directions are, for example, horizontal. The Z-axis direction is, for example, vertical.

[0044] like Figure 2 As shown, the three-dimensional modeling device 200 includes, for example, a modeling unit 210, a cutting unit 270, a stage 280, a position changing unit 282, and a control unit 290.

[0045] The three-dimensional modeling device 200 sprays the plasticized modeling material from the nozzle 260 of the modeling unit 210 onto the stage 280 while simultaneously driving the position changing unit 282 to change the relative position between the nozzle 260 and the stage 280. As a result, the modeling unit 210 shapes the model on the stage 280.

[0046] Furthermore, while rotating the first rotating tool 272 of the cutting unit 270, the three-dimensional modeling apparatus 200 drives the position changing unit 282 to change the relative position between the first rotating tool 272 and the stage 280. The cutting unit 270 then cuts the modeling body formed on the stage 280. In this manner, the three-dimensional modeling apparatus 200 models a molded article 10 with the desired shape. The modeling body is an object in its state before the cavity 12 of the molded article 10 is formed.

[0047] Here, Figure 3 This is a schematic cross-sectional view of the modeling unit 210. (Example) Figure 3 As shown, the shaping unit 210 includes, for example, a material supply unit 220, a plasticizing unit 230, and a nozzle 260.

[0048] The material supply unit 220 supplies molding material to the plasticizing unit 230. The molding material supplied by the material supply unit 220 is in the form of granules or powder, for example. The material supply unit 220 is configured, for example, to include a hopper.

[0049] The plasticizing section 230 includes, for example, a spiral housing 232, a drive motor 234, a flat spiral 240, a barrel 250, and a heater 258. The plasticizing section 230 plasticizes at least a portion of the solid molding material supplied from the material supply section 220 to generate a fluid, paste-like molding material, which is then supplied to the nozzle 260.

[0050] Furthermore, plasticizing is a concept that includes melting, referring to the change of a material from a solid state to a fluid state. Specifically, for materials that will undergo a glass transition, plasticizing refers to the process of raising the material's temperature above its glass transition temperature. For materials that will not undergo a glass transition, plasticizing refers to the process of raising the material's temperature above its melting point.

[0051] The spiral housing 232 is a frame that houses the flat spiral component 240. A cylinder 250 is provided on the lower surface of the spiral housing 232. The flat spiral component 240 is housed in the space enclosed by the spiral housing 232 and the cylinder 250.

[0052] A drive motor 234 is disposed on the upper surface of the spiral housing 232. The drive motor 234 is, for example, a servo motor. The shaft 236 of the drive motor 234 is connected to the upper surface 241 of the flat spiral 240. The drive motor 234 is controlled by a control unit 290. Alternatively, although not shown, the shaft 236 of the drive motor 234 and the upper surface 241 of the flat spiral 240 can also be connected together via a speed reducer.

[0053] The flat helical member 240 has a generally cylindrical shape, smaller in the direction of the rotation axis R than in the direction orthogonal to the rotation axis R. In the illustrated example, the rotation axis R is parallel to the Z-axis. The flat helical member 240 rotates about the rotation axis R using the torque generated by the drive motor 234.

[0054] The flat helical member 240 has an upper surface 241, a groove forming surface 242 opposite to the upper surface 241, and a side surface 243 connecting the upper surface 241 and the groove forming surface 242. A first groove 244 is formed on the groove forming surface 242. The side surface 243 is, for example, perpendicular to the groove forming surface 242. Figure 4 A perspective view is provided to schematically represent the flat helical component 240. Furthermore, for ease of understanding, [the following is also shown]. Figure 4 The text shows the relationship with... Figure 3The state shown is such that the vertical positional relationship is reversed.

[0055] like Figure 4 As shown, a first groove 244 is formed on the groove forming surface 242 of the flat spiral member 240. The first groove 244, for example, has a central portion 245, a connecting portion 246, and a material introduction portion 247. The central portion 245 faces a communicating hole 256 formed on the barrel 250. The central portion 245 communicates with the communicating hole 256. The connecting portion 246 connects the central portion 245 and the material introduction portion 247. In the illustrated example, the connecting portion 246 is arranged in a vortex shape from the central portion 245 toward the outer periphery of the groove forming surface 242. The material introduction portion 247 is provided at the outer periphery of the groove forming surface 242. That is, the material introduction portion 247 is provided on the side surface 243 of the flat spiral member 240. The material supplied from the material supply unit 220 is introduced into the first groove 244 through the material inlet 247, and then conveyed through the connecting part 246 and the central part 245 to the communicating hole 256 formed on the barrel 250. For example, two first grooves 244 are provided.

[0056] Furthermore, the number of first grooves 244 is not specifically limited. Although not illustrated, there can be three first grooves 244, or there can be only one.

[0057] like Figure 3 As shown, the barrel 250 is positioned below the flat helical member 240. The barrel 250 has a counterface 252 opposite to the groove forming surface 242 of the flat helical member 240. At the center of the counterface 252, a connecting hole 256 communicating with the first groove 244 is formed. Here, Figure 5 A schematic top view of the barrel 250.

[0058] like Figure 5 As shown, a second groove 254 and a connecting hole 256 are formed on the opposing surface 252 of the barrel 250. Multiple second grooves 254 are formed. Although six second grooves 254 are formed in the illustrated example, the number of second grooves 254 is not particularly limited. When viewed from the Z-axis direction, the multiple second grooves 254 are formed around the connecting hole 256. One end of each second groove 254 connects to the connecting hole 256 and extends in a spiral pattern from the connecting hole 256 toward the outer periphery of the barrel 250. The second groove 254 functions to guide the plasticized molding material toward the connecting hole 256.

[0059] Furthermore, the shape of the second groove 254 is not particularly limited, and it may, for example, be a straight line. Additionally, the second groove 254 may not necessarily have one end connected to the connecting hole 256. Moreover, the second groove 254 may not necessarily be formed on the opposing surface 252. However, if efficient guidance of the plasticized molding material into the connecting hole 256 is desired, it is preferable that the second groove 254 be formed on the opposing surface 252.

[0060] like Figure 3 As shown, a heater 258 is disposed on the barrel 250. The heater 258 heats the material supplied between the flat auger 240 and the barrel 250. The heater 258 is controlled by a control unit 290. The plasticizing unit 230 heats the molding material as it is fed toward the connecting hole 256 via the flat auger 240, the barrel 250, and the heater 258, thereby generating plasticized molding material, which then flows out of the connecting hole 256. When viewed from the Z-axis direction, the heater 258 may also be annular in shape.

[0061] Alternatively, the heater 258 may not be mounted on the barrel 250; for example, it may be mounted on the flat helical member 240. Furthermore, although not shown in the figure, the plasticizing section 230 may replace the aforementioned flat helical member 240, and a relatively long coaxial screw in the direction of rotation may be used to plasticize the molding material.

[0062] A nozzle 260 is positioned below the barrel 250. A nozzle orifice 262 is formed in the nozzle 260. The nozzle orifice 262 communicates with a connecting hole 256. Molding material is supplied through the nozzle orifice 262 and the connecting hole 256. The nozzle 260 ejects the plasticized molding material from the nozzle orifice 262 toward the stage 280. Thus, the molding unit 210 shapes the object on the stage 280.

[0063] like Figure 2 As shown, the cutting unit 270 rotates a first rotary tool 272 mounted at the top end of the stage 280 to cut the modeled object formed on the stage 280. The cutting unit 270 cuts the modeled object to create a molded article 10 with a cavity 12. The first rotary tool 272 is capable of rotating about an axis parallel to the Z-axis. For example, a flat-end mill or a ball-end mill can be used as the first rotary tool 272. The control unit 290 controls the cutting position by controlling the position changing unit 282, thereby changing the relative position between the first rotary tool 272 and the modeled object formed on the stage 280.

[0064] A molded article 10 is disposed on the stage 280. In the illustrated example, the molded article 10 is directly disposed on the stage 280. Alternatively, although not illustrated, the molded article 10 may also be disposed on the stage 280 via a predetermined plate.

[0065] The position changing unit 282 supports the stage 280. In the illustrated example, the position changing unit 282 is configured as a three-axis positioner that moves the stage 280 relative to the modeling unit 210 and the cutting unit 270 along three mutually orthogonal axes.

[0066] Alternatively, the position changing unit 282 may not move the stage 280, but instead move the modeling unit 210 and the cutting unit 270 relative to the stage 280. Furthermore, the position changing unit 282 may move both the stage 280 and both the modeling unit 210 and the cutting unit 270. For example, the position changing unit 282 may move the stage 280 in the X-axis and Y-axis directions, and move the modeling unit 210 and the cutting unit 270 in the Z-axis direction.

[0067] The position changing unit 282 may also have the function of tilting the stage 280 relative to the horizontal plane. The position changing unit 282 may also have the function of tilting the nozzle 260 and the first rotating tool 272 relative to the horizontal plane.

[0068] The control unit 290 may be configured, for example, as a computer having a processor, main storage device, and an input / output interface for implementing signals to and from the outside. The control unit 290 controls the modeling unit 210, the cutting unit 270, and the position changing unit 282, for example, by executing a program read from the main storage device through the processor. Alternatively, the control unit 290 may not be configured as a computer, but rather as a combination of multiple circuits.

[0069] Here, Figure 6 A cross-sectional view schematically showing the manufacturing process of the molded article 10 in the three-dimensional modeling device 200.

[0070] like Figure 6 As shown, the control unit 290 maintains the distance between the stage 280 and the nozzle 260 while simultaneously changing the position of the nozzle 260 relative to the stage 280 in the direction along the upper surface of the stage 280, causing the plasticized molding material to be ejected from the nozzle 260. The molding material ejected from the nozzle 260 is continuously deposited on the stage 280 in the moving direction of the nozzle 260, thereby forming layer 14.

[0071] The control unit 290 repeatedly scans the nozzle 260 to form multiple layers 14. Specifically, after forming one layer 14, the control unit 290 moves the nozzle 260 upward relative to the stage 280. Then, by further accumulating layers 14 on top of the layer 14 formed so far, a molded article 10 composed of multiple layers 14 is formed. The molded article 10 is a laminate composed of multiple layers 14.

[0072] In situations such as when the control unit 290 moves the nozzle 260 upward after a layer 14 has been accumulated, or when molding is performed in a discontinuous cycle, the ejection of molding material from the nozzle 260 may be temporarily interrupted. In such cases, the control unit 290 controls a butterfly valve (not shown) installed in the nozzle orifice 262 to stop the ejection of molding material from the nozzle 260. After changing the position of the nozzle 260, the control unit 290 restarts the ejection of molding material by opening the butterfly valve, thereby restarting the accumulation of molding material from the changed position of the nozzle 260.

[0073] 1.3. Injection Molding Equipment

[0074] Figure 7 The side view of the injection molding apparatus 300 of the modeling recycling system 100 is shown schematically. The injection molding apparatus 300 is used, for example, as part of a movable mold 342 for the molded article 10 modeled in the three-dimensional modeling apparatus 200.

[0075] like Figure 7 As shown, the injection molding apparatus 300 includes, for example, a material supply unit 310, an injection unit 320, a mold unit 330, a mold closing unit 360, and a control unit 370.

[0076] The material supply unit 310 supplies materials, which become raw materials, to the injection molding unit 320. The material supply unit 310 is, for example, composed of a hopper. The material supplied from the material supply unit 310 is, for example, in granular or powder form. The materials supplied from the material supply unit 310 are, for example, acrylonitrile-butadiene-styrene (ABS) resin, polyphenylene sulfide (PPS), and materials obtained by adding metal particles to these materials.

[0077] The injection molding section 320 plasticizes the material supplied from the material supply section 310, thereby setting it as the plasticized material. Furthermore, the injection molding section 320 injects the plasticized material toward the mold section 330.

[0078] In the mold section 330, a cavity corresponding to the shape of the molded article is formed. Material injected from the injection section 320 flows into the cavity. Then, the plasticized material is cooled to solidify, thereby forming the molded article.

[0079] The mold closing section 360 opens and closes the molding die of the mold section 330. After the plasticized material has cooled and solidified, the mold closing section 360 opens the molding die of the mold section 330. As a result, the molded article is discharged to the outside.

[0080] The control unit 370 may be configured as, for example, a computer having a processor, main storage, and an input / output interface for inputting and outputting signals to and from the outside. The control unit 370 performs various functions, for example, by having the processor execute programs loaded into the main storage. Specifically, the control unit 370 controls the injection molding unit 320 and the mold closing unit 360. Alternatively, the control unit 370 may not be configured as a computer, but rather as a combination of multiple circuits.

[0081] Figure 8 To schematically illustrate the injection molding apparatus 300 Figure 7 A sectional view along line VIII-VIII. (See example.) Figure 8 As shown, the injection molding section 320 includes, for example, a plasticizing section 322, an injection molding mechanism 324, and a nozzle 328.

[0082] The plasticizing section 322 is configured to plasticize the material supplied from the material supply section 310 into a flowable paste and guide it to the injection molding mechanism 324. The structure and function of the plasticizing section 322 are basically the same as those of the plasticizing section 230 of the three-dimensional molding device 200 described above. That is, the plasticizing section 322 has a drive motor, a flat helical component, a barrel, and a heater.

[0083] The injection molding mechanism 324 includes, for example, a cylinder 325, a plunger 326, and a plunger drive unit 327. The cylinder 325 is a generally cylindrical component connected to the communication hole 323 of the plasticizing section 322. The plunger 326 moves inside the cylinder 325. The plunger 326 is driven by the plunger drive unit 327, which is composed of a motor and gears, etc. The plunger drive unit 327 is controlled by a control unit 370. Alternatively, the cylinder 325 may be connected to a flow channel downstream of the communication hole 323.

[0084] The injection molding mechanism 324 performs metering and injection operations by sliding the plunger 326 within the cylinder 325. The metering operation involves moving the plunger 326 along the -X-axis direction away from the connecting hole 323, thereby guiding the plasticized material in the connecting hole 323 into the cylinder 325 and metering the material within the cylinder 325. The injection operation involves moving the plunger 326 along the +X-axis direction closer to the connecting hole 323, thereby injecting the plasticized material from the cylinder 325 into the mold section 330 via the nozzle 328.

[0085] A nozzle orifice 329 communicating with the connecting hole 323 is formed in the nozzle 328. The nozzle 328 injects material supplied from the plasticizing section 322 toward the molding die 340 of the mold section 330. Specifically, by performing the above-described metering and injection operations, the material metered in the cylinder 325 is conveyed from the injection molding mechanism 324 through the connecting hole 323 to the nozzle orifice 329. Furthermore, the material is injected from the nozzle orifice 329 into the molding die 340.

[0086] The mold section 330 includes a forming mold 340 and an extrusion mechanism 350. Material fed into the nozzle orifice 329 is injected from the nozzle orifice 329 into the cavity 12 of the forming mold 340. Specifically, the forming mold 340 has a movable mold 342 and a fixed mold 346 facing each other, and a cavity 12 is provided between the movable mold 342 and the fixed mold 346. The cavity 12 is a space corresponding to the shape of the molded article formed in the injection molding apparatus 300. Here, Figure 9 An exploded perspective view of the movable mold 342 of the forming mold 340 is shown schematically.

[0087] like Figure 9 As shown, the movable mold 342 of the forming mold 340 includes, for example, a molded article 10 and a female mold 343. The molded article 10 is a molded article formed in the three-dimensional modeling device 200 described above. The molded article 10 is a core. The molded article 10 has a first part 16 that forms a cavity 12 and a second part 18 that does not form a cavity 12. The first part 16 is the surface of the molded article 10 that defines the cavity 12. A test piece 20 is attached to the molded article 10. The test piece 20 is integrally provided with the molded article 10. The test piece 20 is, for example, a test piece for tensile testing, compression testing, etc. In addition, for ease of understanding, therefore... Figure 2 The illustration of test piece 20 is omitted.

[0088] like Figure 9 As shown, the movable mold 342 of the molding die 340 is formed by fitting the molded article 10 into the recess 344 formed on the female mold 343. Before fitting the molded article 10 into the recess 344, the test piece 20 is broken off and removed from the molded article 10. The material of the female mold 343 is, for example, metal. Alternatively, although not shown, the test piece 20 may be separately provided from the molded article 10. In this case, the operation of breaking off and removing the test piece 20 from the molded article 10 can be omitted.

[0089] like Figure 8As shown, an extrusion mechanism 350 is mounted on a movable mold 342. The extrusion mechanism 350 causes the molded article formed in the injection molding apparatus 300 to be demolded from the mold 340. The extrusion mechanism 350 includes, for example, a push rod 351, a support plate 352, a support bar 353, a spring 354, an extrusion plate 355, and a thrust bearing 356.

[0090] The push rod 351 is a rod-shaped component used to eject the molded article formed in the cavity 12. The push rod 351 is arranged to pass through the movable mold 342 and insert into the cavity 12.

[0091] The support plate 352 is a plate component that supports the push rod 351. The push rod 351 is fixed to the support plate 352. The support rod 353 is fixed to the support plate 352. The support rod 353 is inserted into a through hole formed in the movable mold 342.

[0092] Spring 354 is disposed in the space between movable mold 342 and support plate 352. Spring 354 is inserted therein by support rod 353. During forming, spring 354 applies force to support plate 352 in such a way that the head of push rod 351 becomes part of the wall of cavity 12.

[0093] The extrusion plate 355 is fixed to the support plate 352. A thrust bearing 356 is mounted on the extrusion plate 355. The thrust bearing 356 is designed to prevent damage to the extrusion plate 355 from the head of the ball screw portion 364. Alternatively, a thrust sliding bearing or the like can be used instead of the thrust bearing 356.

[0094] The mold closing unit 360 includes, for example, a mold drive unit 362 and a ball screw unit 364. The mold drive unit 362 is composed of, for example, a motor, gears, etc. The mold drive unit 362 is connected to the movable mold 342 via the ball screw unit 364. The mold drive unit 362 is controlled by a control unit 370. The ball screw unit 364 transmits the power generated by driving the mold drive unit 362 to the movable mold 342. The mold closing unit 360 moves the movable mold 342 using the mold drive unit 362 and the ball screw unit 364, thereby opening and closing the forming mold 340.

[0095] 1.4. Cutting device

[0096] Figure 10 This is a perspective view schematically illustrating the cutting device 400 of the model recycling system 100. The cutting device 400 cuts the molded article 10, which is used as part of the movable mold 342 in the injection molding apparatus 300, and generates recycled material that is reused as modeling material in the three-dimensional modeling apparatus 200.

[0097] like Figure 10 As shown, the cutting device 400 includes, for example, a cutting unit 410, a stage 420, a position changing unit 430, and a control unit 440.

[0098] While rotating the second rotating tool 412 of the cutting unit 410, the cutting device 400 drives the position changing unit 430 to change the relative position between the second rotating tool 412 and the stage 420. Furthermore, as... Figure 11 As shown, the cutting unit 410 cuts the molded article 10 formed on the stage 420. As a result, the cutting unit 410 generates reusable material 30. The reusable material 30 consists of the cutting chips from the molded article 10. In the illustrated example, the reusable material 30 is granular. Furthermore, Figure 11 The figure illustrates the cutting of the formed article 10 performed by the second rotary tool 412 of the cutting device 400.

[0099] Here, Figure 12 A bottom view of the second rotating tool 412 is shown schematically. Figure 13 A side view of the second rotating tool 412 is shown schematically.

[0100] like Figure 12 As shown, the second rotating tool 412 has, for example, multiple blades 414. In the illustrated example, the second rotating tool 412 has three blades 414. Figure 13 As shown, the second rotary tool 412 has a roughing structure with uneven surfaces formed on the surface of the cutting edge 414. In the illustrated example, the second rotary tool 412 is a three-bladed roughing end mill. The first rotary tool 272 of the aforementioned three-dimensional modeling device 200 may also have the same shape as the second rotary tool 412.

[0101] like Figure 10 As shown, a molded article 10 is disposed on a stage 420. In the illustrated example, the molded article 10 is directly disposed on the stage 420. The stage 420 has a magnet portion 422. In the illustrated example, the molded article 10 is disposed on the magnet portion 422. The magnet portion 422 is, for example, constructed of a neodymium magnet. When the molded article 10 contains metal particles, the magnet portion 422 uses magnetic force to recover the metal particles of the reusable material 30 generated from the molded article 10.

[0102] The structure and function of the position changing unit 430 are basically the same as those of the position changing unit 282 of the three-dimensional modeling device 200 described above. The structure and function of the control unit 440 are basically the same as those of the control unit 290 of the three-dimensional modeling device 200 described above.

[0103] 2. Manufacturing methods for decorative items

[0104] 2.1. Overall Process

[0105] Figure 14 This is a flowchart used to explain the manufacturing method of the shaped article according to this embodiment.

[0106] like Figure 14 As shown, the method for manufacturing a molded article according to this embodiment includes: a first step, namely step S1, spraying out a molding material containing thermoplastic resin to shape a molded body, and cutting the molded body using a first rotating tool 272 to form a first molded article; a second step, namely step S2, cutting the first molded article using a second rotating tool 412 to generate reusable material; and a third step, namely step S3, spraying out the plasticized reusable material to form a second molded article. Each step will be described below.

[0107] 2.2. First Process

[0108] In the first process, use Figure 2 The three-dimensional modeling device 200 of the modeling recycling system 100 sprays modeling material to shape the model body. Then, the model body is cut using the first rotating tool 272 of the three-dimensional modeling device 200 to form a first molded product. Specifically, the control unit 290 of the three-dimensional modeling device 200 controls the drive unit that rotates the first rotating tool 272 to rotate the first rotating tool 272. Furthermore, the control unit 290 controls the position changing unit 282 to move the first rotating tool 272 relative to the stage 280, thereby bringing the first rotating tool 272 into contact with the model body to cut the model body.

[0109] The molding materials include thermoplastic resins. Examples of thermoplastic resins include general-purpose engineering plastics and super engineering plastics.

[0110] Examples of general-purpose engineering plastics include ABS resin, polypropylene (PP), polyethylene (PE), polyoxymethylene (POM), polyvinyl chloride (PVC), polyamide (PA), polylactic acid (PLA), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, and polyterephthalic acid.

[0111] Examples of super engineering plastics include polysulfone (PSU), polyethersulfone (PES), PPS, polyphenylene sulfide (PPS), polyarylate (PAR), polyimide (PI), polyamide-imide (PAI), polyetherimide (PEI), and polyether ether ketone (PEEK).

[0112] The shaping material can also contain metal particles. For example, the metal particles contained in the shaping material are amorphous metal particles with iron (Fe) as the main component. That is, iron contains more than 70% by mass in the amorphous metal particles. Other amorphous metal particles that can be added to the main component include cobalt (Co), nickel (Ni), silicon (Si), boron (B), chromium (Cr), tungsten (W), niobium (Nb), tantalum (Ta), titanium (Ti), zirconium (Zr), and hafnium (Hf).

[0113] The amorphous metal particles contained in the molding material are, for example, spherical. These amorphous metal particles are formed, for example, by atomization. By atomization, spherical amorphous metal particles can be obtained.

[0114] The content of amorphous metal particles in the molding material is, for example, 20% by volume or more and 40% by volume or less, preferably 30% by volume or more and 40% by volume or less, and more preferably 35% by volume or more and 40% by volume or less.

[0115] A solvent can also be applied to the amorphous metal particles contained in the molding material. For example, a silane coupling agent can be applied to the amorphous metal particles. The silane coupling agent can be, for example, 3-mercaptopropyltrimethoxysilane.

[0116] 2.3. Second Process

[0117] In the second process, use Figure 10 The cutting device 400 of the molded article recycling system 100 shown generates reusable material by cutting the first molded article using a second rotating tool 412. In the second process, for example, [the material is processed as...]. Figure 8 The movable mold 342 of the injection molding device 300 of the model recycling system 100 shown is used to cut a first molded article.

[0118] In the second process, the first formed product is cut under the first condition that the moving speed of the second rotating tool 412 is faster than the moving speed of the first rotating tool 272 in the first process. Specifically, Figure 10 The control unit 440 of the cutting apparatus 400 shown controls the position changing unit 430 in such a way that the moving speed of the second rotary tool 412 relative to the stage 420 is faster than the moving speed of the first rotary tool 272 relative to the stage 280 in the first process, so as to cut the first molded article. The moving speed of the second rotary tool 412 in the second process is, for example, 1200 mm / min or more and 10800 mm / min or less.

[0119] In the second process, the first molded product is cut under a second condition where the rotational speed of the second rotating tool 412 is slower than the rotational speed of the first rotating tool 272 in the first process. Specifically, the control unit 440 controls the drive unit that rotates the second rotating tool 412 in such a way that the rotational speed of the second rotating tool 412 is slower than the rotational speed of the first rotating tool 272 in the first process, thereby causing the second rotating tool 412 to rotate. The rotational speed of the second rotating tool 412 is, for example, 100 rpm or more and 900 rpm or less.

[0120] In the second process, the first molded article is cut under at least one of the first and second conditions. That is, in the second process, the first molded article can be cut under both the first and second conditions, or under the second condition without using the first condition, or under the first condition without using the second condition.

[0121] In the second process, for example, the ratio of the moving speed (mm / min) of the second rotating tool 412 to the rotational speed (rpm) of the second rotating tool 412 is 12 or more. And, for example, this ratio is 100 or less.

[0122] In the second process, the second portion 18 of the molded article 10, which does not constitute the cavity 12, is cut to generate reusable material 30. Specifically, the control unit 440 controls the position changing unit 430 to make the second rotating tool 412 contact the second portion 18. For example, about 1 mm is cut off the first portion 16 that defines the cavity 12, and the remaining second portion 18 is used to generate reusable material.

[0123] When the molding material contains metal particles such as iron, the cutting chips of the first molded article are collected in the second process by the magnetic force of the magnet part 422. This suppresses the scattering of cutting chips during cutting.

[0124] Alternatively, in the second process, the cutting unit 270 of the three-dimensional modeling device 200 can be used instead of the cutting device 400 to cut the first molded article using the first rotary tool 272, thereby generating reusable material. In this case, the rotary tool used in the first process and the rotary tool used in the second process are the same first rotary tool 272.

[0125] In addition, the chips generated in the second process can be processed using a crusher or extruder to obtain reusable materials.

[0126] 2.4. Third process

[0127] In the third process, use Figure 2 The three-dimensional modeling apparatus 200 shown plasticizes the recycled material generated in the second process. Furthermore, using the three-dimensional modeling apparatus 200, the plasticized recycled material is sprayed onto the stage 280, thereby forming a second molded article. The shape of the second molded article can be the same as or different from the first molded article. The material of the second molded article can be the same as or different from the first molded article.

[0128] In the third process, for example, the recycled material obtained with added additives is plasticized and sprayed out. Examples of additives include plasticizing accelerators and metal particles contained in the molding material of the first process. It can also be assumed that the more times the molded product is recycled, the greater the amount of additives should be.

[0129] In the third process, the test piece, which is integral with or separate from the second molded product, is shaped.

[0130] The above processes enable the recycling of molded products. The number of times a molded product can be recycled is not specifically limited.

[0131] 2.5. Effects

[0132] The method for manufacturing a molded article includes: a first step of spraying a molding material containing thermoplastic resin to shape a molding body, and cutting the molding body using a first rotating tool 272 to form a first molded article; a second step of cutting the first molded article using a second rotating tool 412 to generate reusable material; and a third step of spraying the plasticized reusable material to form a second molded article. In the second step, the first molded article is cut under at least one of the following conditions: the moving speed of the second rotating tool 412 is faster than the moving speed of the first rotating tool 272 in the first step, and the rotational speed of the second rotating tool 412 is slower than the rotational speed of the first rotating tool 272 in the first step.

[0133] Therefore, in the manufacturing method of molded articles, as shown in the experimental examples described later, the possibility of recycled materials becoming vortex-shaped can be reduced. Consequently, during the plasticization of recycled materials, the possibility of interference between recycled materials leading to bridging can be reduced, thereby enabling stable plasticization of the recycled materials.

[0134] In the method for manufacturing a molded article, the second rotary tool 412 has a cutting edge 414 with a roughing structure. Therefore, in the method for manufacturing a molded article, it is possible to suppress the situation where the length of the recycled material is too long. If the cutting edge of the second rotary tool does not have a roughing structure, the excessive length of the recycled material will increase the possibility of bridging during the plasticization of the recycled material.

[0135] In the method for manufacturing the molded article, in the second step, the ratio of the moving speed (mm / min) of the second rotating tool 412 to its rotational speed (rpm) is 12 or more. Therefore, in the method for manufacturing the molded article, as shown in the experimental examples described later, the possibility of recycled materials becoming vortex-shaped can be reduced.

[0136] In the method for manufacturing molded articles, the molding material includes amorphous metal particles with iron as the main component. Amorphous metals have lower thermal conductivity than metals and higher thermal conductivity than resins. Therefore, in the method for manufacturing molded articles, compared to using molding materials composed of resins, it is possible to reduce the heat retained in the molded article, thereby shortening the cooling time. Furthermore, compared to using molding materials composed of metals, it is possible to mold articles that are less prone to incomplete filling and warping.

[0137] In the manufacturing method of the molded article, the amorphous metal particles are spherical in shape. Therefore, compared with the case where the amorphous metal particles are not spherical, it is possible to form a molded article with a smaller difference in elastic modulus in the mutually orthogonal first and second directions.

[0138] Furthermore, it is possible to increase the size of the amorphous metal particles contained in the first molded article to be the same as the size of the amorphous metal particles contained in the second molded article obtained using recycled materials. For example, if the amorphous metal particles are fibrous, the amorphous metal particles are cut in the second process, thereby increasing the likelihood that the amorphous metal particles contained in the second molded article are smaller compared to the size of the amorphous metal particles contained in the first molded article.

[0139] In the method for manufacturing a molded article, at least one of the first molded article and the second molded article is at least a portion of the molding die 340 used in the injection molding apparatus 300. Therefore, in the method for manufacturing a molded article, at least a portion of the molding die 340 can be molded.

[0140] In the method for manufacturing a molded article, the first molded article is at least a portion of the molding die 340 having a cavity 12. In a second step, the second portion 18 of the first molded article that does not constitute the cavity 12 is cut to generate reusable material. Therefore, in the method for manufacturing a molded article, reusable material can be generated without using the portion that has deteriorated significantly due to injection molding. The first portion 16 of the first molded article that constitutes the cavity 12 deteriorates more significantly than the second portion 18 because it comes into contact with the high-temperature molding material after plasticization.

[0141] In the method for manufacturing molded articles, in the third step, recycled material obtained by adding additives is plasticized and sprayed out. Therefore, in the method for manufacturing molded articles, it is possible to make the composition of the material constituting the second molded article similar to the composition of the material constituting the first molded article.

[0142] In the method for manufacturing a molded article, a test piece 20, which is integral with or separate from the second molded article, is shaped. Therefore, in the method for manufacturing a molded article, by testing the test piece 20, it is possible to investigate whether the physical properties of the second molded article deviate from those of the first molded article.

[0143] In the manufacturing method of the molded article, the molding material contains metal particles, and in the second process, magnetic force is used to collect the cutting chips from the first molded article. Therefore, it is possible to suppress the scattering of cutting chips during cutting.

[0144] 3. Experimental Example

[0145] 3.1 Experimental Conditions

[0146] Figure 15 This is a three-dimensional diagram used to illustrate the experimental example. Figure 16 This is a side view used to illustrate the experimental example. Additionally, for ease of understanding, [the view is shown in the original text]. Figure 15 as well as Figure 16 In the diagram, the rotation tool T is illustrated in a simplified manner. (See diagram below.) Figure 15 as well as Figure 16 As shown, a rotary tool T was used to cut the workpiece W, and the shape of the cutting chips was investigated. The material of the workpiece W was obtained by adding metal particles to PPS. The metal particle content was 40% by volume. As the metal particles, the atomizing powder "KUAMET" manufactured by Epson Atmix Co., Ltd. was used.

[0147] While rotating the rotary tool T around a rotation axis C parallel to the Z-axis, it is also moved relative to the workpiece W in the +Y-axis direction to cut the workpiece W. For example... Figure 16As shown, the cutting depth G of the rotary tool T relative to the workpiece W in the Z-axis direction is set to 3mm. Then, the rotary tool T is moved in the +X-axis direction by an amount corresponding to the side step D, and again moved in the +Y-axis direction relative to the workpiece W to cut the workpiece W.

[0148] Figure 17 A photograph showing the appearance of the rotating tool T. (Example) Figure 17 As shown, the rotary tool T has three cutting edges B. The rotary tool T is a three-edged roughing end mill. The diameter of the rotary tool T is 16 mm.

[0149] Figure 18 as well as Figure 19 A table representing cutting conditions. For example... Figure 18 as well as Figure 19 As shown, the cutting conditions are labeled as Condition 1 to Condition 16. Figure 18 Conditions 1 through 8 are shown. Figure 19 Conditions 9 through 16 are shown.

[0150] exist Figure 18 as well as Figure 19 In this context, "rotational speed" refers to the rotational speed of the rotary tool (rpm). "traverse speed" refers to the movement speed of the rotary tool T relative to the workpiece W in the +Y axis direction (mm / min). "circumferential speed" refers to the surface velocity produced by the rotation of the rotary tool (m / min). "Work done / cutting edge" is the value obtained by dividing "traverse speed" by "rotational speed" and the number of cutting edges, i.e., "3". "Ratio (traverse speed / rotational speed)" is the value obtained by dividing "traverse speed" by "rotational speed".

[0151] 3.2. Experimental Results

[0152] Figure 20 These are photographs of the cutting chips generated when the workpiece W is cut under conditions 1 to 6. Figure 21 These are photographs of the cutting chips generated when the workpiece W is cut under conditions 7 to 12. Figure 20 as well as Figure 21 The photo's magnification is 20x. Additionally, although in Figure 20 as well as Figure 21 No photographs of the chips from conditions 13 to 16 are shown, but the chips from conditions 13 to 16 have the same shape as those from condition 12.

[0153] like Figure 20 as well as Figure 21As shown, the smaller the ratio of (traverse speed / rotational speed), the more easily the cutting chips form a vortex shape. Under condition 12, where the ratio of (traverse speed / rotational speed) = 12, vortex-shaped cutting chips can no longer be detected. This experiment demonstrates that a faster tracer speed and a slower rotational speed reduce the number of vortex-shaped cutting chips.

[0154] Under conditions 12 to 16, where the ratio (moving speed / rotational speed) = 12, it can be said that condition 16, which has the fastest moving speed, is preferred if productivity is taken into account.

[0155] The above-described embodiments and modifications are examples and are not intended to limit the scope of the embodiments. For example, appropriate combinations of the embodiments and modifications may be made.

[0156] This invention includes structures that are substantially the same as those described in the embodiments, such as structures with the same function, method, and result, or structures with the same purpose and effect. Furthermore, this invention includes structures that replace non-essential parts of the structures described in the embodiments. Furthermore, this invention includes structures that can achieve the same effect as those described in the embodiments, or structures that can achieve the same purpose. Furthermore, this invention includes structures that incorporate known techniques into the structures described in the embodiments.

[0157] Based on the above implementation methods and variations, the following can be derived.

[0158] One method for manufacturing forming molds includes:

[0159] In the first step, a molding material containing thermoplastic resin is sprayed out to shape the molding body, and the molding body is cut by using a first rotating tool to form a first molded product.

[0160] The second step involves using a second rotating tool to cut the first molded article, thereby generating reusable material.

[0161] The third step involves spraying out the plasticized recycled material to form the second molded article.

[0162] In the second step, the first molded article is cut under at least one of the following conditions: the moving speed of the second rotating tool is faster than the moving speed of the first rotating tool in the first step, and the rotating speed of the second rotating tool is slower than the rotating speed of the first rotating tool in the first step.

[0163] According to the manufacturing method of this molded article, the possibility of recycled materials becoming vortex-shaped can be reduced.

[0164] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0165] The second rotary tool has a cutting edge with a roughing structure.

[0166] According to the manufacturing method of this molded article, it is possible to suppress the excessive length of recycled materials in the longitudinal direction.

[0167] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0168] In the second process, the ratio of the moving speed (mm / min) of the second rotating tool to its rotational speed (rpm) is 12 or more.

[0169] According to the manufacturing method of this molded article, the possibility of recycled materials becoming vortex-shaped can be reduced.

[0170] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0171] The shaping material contains amorphous metal particles with iron as the main component.

[0172] According to the manufacturing method of this molded article, the heat retained in the molded article can be reduced, thereby shortening the cooling time of the molded article, and producing a molded article that is less prone to poor filling and warping.

[0173] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0174] The amorphous metal particles are spherical in shape.

[0175] According to the manufacturing method of this molded article, it is possible to form a molded article with a small difference in elastic modulus in a first orthogonal direction and a second direction.

[0176] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0177] At least one of the first molded article and the second molded article is at least a portion of a molding die used in an injection molding apparatus.

[0178] According to the manufacturing method of the molded article, at least a part of the molding die can be formed.

[0179] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0180] The first molded article is at least a portion of a molding die having a cavity.

[0181] In the second process, the portion of the first molded article that does not constitute the cavity is cut to generate the reusable material.

[0182] According to the manufacturing method of this molded article, it is possible to generate reusable materials without using parts that are severely degraded due to injection molding.

[0183] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0184] In the third step, the recycled material obtained by adding additives is plasticized and sprayed out.

[0185] According to the manufacturing method of this molded article, the composition of the material constituting the second molded article can be made similar to the composition of the material constituting the first molded article.

[0186] In one method of manufacturing the forming mold, the test piece, which is integral with or separate from the second molded article, can also be shaped in the third step.

[0187] According to the manufacturing method of the molded article, by testing the test piece, it is possible to investigate whether the physical properties of the second molded article deviate from those of the first molded article.

[0188] In one method of manufacturing a forming mold, the following approach can also be adopted, namely,

[0189] The shaping material contains metal particles.

[0190] In the second process, magnetic force is used to recover the cutting chips from the first molded article.

[0191] According to the manufacturing method of this molded article, it is possible to suppress the scattering of cutting chips during cutting.

[0192] Symbol Explanation

[0193] 10…Molded article; 12…Cavity; 14…Layer; 16…First part; 18…Second part; 20…Test piece; 30…Recycled material; 100…Modeling recycling system; 200…Three-dimensional modeling device; 210…Modeling unit; 220…Material supply unit; 230…Plasticizing unit; 232…Spiral shell; 234…Drive motor; 236…Shaft; 240…Flat spiral; 241…Upper surface; 242…Groove 243…Side surface; 244…First groove; 245…Central section; 246…Connecting section; 247…Material inlet section; 250…Barrel; 252…Opposing surface; 254…Second groove; 256…Connecting hole; 258…Heater; 260…Nozzle; 262…Nozzle orifice; 270…Cutting unit; 272…First rotary tool; 280…Stage; 282…Position changing section; 290…Control section; 300…Injection molding apparatus; 310…Material supply unit; 320…Injection molding unit; 322…Plasticizing unit; 323…Connecting hole; 324…Injection mechanism; 325…Cylinder; 326…Plunger; 327…Plunger drive unit; 328…Nozzle; 329…Nozzle orifice; 330…Mold unit; 340…Forming die; 342…Modible die; 343…Mother mold; 344…Recess; 346…Fixed die; 350…Extrusion Mechanism; 351…Push rod; 352…Support plate; 353…Support bar; 354…Spring; 355…Extrusion plate; 356…Thrust bearing; 360…Mold closing part; 362…Mold drive part; 364…Ball screw part; 370…Control part; 400…Cutting device; 410…Cutting unit; 412…Second rotary tool; 420…Stage; 422…Magnet part; 430…Position changing part; 440…Control part.

Claims

1. A method for manufacturing a molded article, comprising: In the first step, a molding material containing thermoplastic resin is sprayed out to shape the molding body, and the molding body is cut by using a first rotating tool to form a first molded product. The second step involves using a second rotating tool to cut the first molded article, thereby generating reusable material. The third step involves spraying out the plasticized recycled material to form the second molded article. In the second step, the first molded article is cut under at least one of the following conditions: the moving speed of the second rotating tool is faster than the moving speed of the first rotating tool in the first step, and the rotating speed of the second rotating tool is slower than the rotating speed of the first rotating tool in the first step.

2. The method for manufacturing a molded article as described in claim 1, wherein, The second rotary tool has a cutting edge with a roughing structure.

3. The method for manufacturing a molded article as described in claim 1 or 2, wherein, In the second process, the ratio of the moving speed of the second rotating tool to the rotational speed of the second rotating tool is 12 or more, wherein the moving speed is in mm / min and the rotational speed is in rpm.

4. The method for manufacturing a molded article as described in claim 1 or 2, wherein, The shaping material contains amorphous metal particles with iron as the main component.

5. The method for manufacturing a molded article as described in claim 4, wherein, The amorphous metal particles are spherical in shape.

6. The method for manufacturing a molded article as described in claim 1 or 2, wherein, At least one of the first molded article and the second molded article is at least a portion of a molding die used in an injection molding apparatus.

7. The method for manufacturing a molded article as described in claim 6, wherein, The first molded article is at least a portion of a molding die having a cavity. In the second process, the portion of the first molded article that does not constitute the cavity is cut to generate the reusable material.

8. The method for manufacturing a molded article as described in claim 1 or 2, wherein, In the third step, the recycled material obtained by adding additives is plasticized and sprayed out.

9. The method for manufacturing a molded article as described in claim 1 or 2, wherein, In the third process, the test piece, which is integral with or separate from the second molded article, is shaped.

10. The method for manufacturing a molded article as described in claim 1 or 2, wherein, The shaping material contains metal particles. In the second process, magnetic force is used to recover the cutting chips from the first molded article.

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