Molding plate, molding part, and method for producing same

Abstract

The invention relates to a model plate, a model part and a manufacturing method of the model plate and the model part. For example, the invention provides a novel structure for carrying out surface processing on accessories contained in the model plate or accessories as the model part. This mold plate is provided with a flow path, and a predetermined accessory (mold member) which is connected to the flow path and has a roughened surface. In addition, a mold for molding the predetermined accessory is manufactured by electrical discharge machining, and the surface of the electrical discharge electrode subjected to electrical discharge machining is subjected to surface machining for roughening treatment.

Description

Technical Field

[0001] This invention relates to model plates, model components, and methods for manufacturing them. Background Technology

[0002] Model toys utilize a variety of accessories, each made from a different synthetic resin. This allows for the creation of model toys by combining accessories of varying textures and colors. These accessories are formed as model plates, which are created by connecting multiple accessories to runners. During assembly, each accessory is removed from the runners for use.

[0003] The aforementioned model panels are manufactured by flowing synthetic resin into a mold and forming it. In such model panels, there are cases where one model panel is formed using a single synthetic resin, and cases where one model panel is formed using multiple different synthetic resins. Patent Document 1 discloses a model panel having multiple flow channels formed by assembling model structural components made of synthetic resin using the same synthetic resin.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Utility Model Publication No. 06-7745 Summary of the Invention

[0007] The problem the invention aims to solve

[0008] In the aforementioned prior art, while it is possible to include components made of different synthetic resins within a single mold plate, it has not been studied how to include components with different tactile textures within a single mold plate through surface finishing. Alternatively, it has not been studied how to include portions with different tactile textures on the surface of a single component. For example, when performing surface finishing to roughen the surface of the mold plate, it is considered to perform the finishing on the surface of each molded part individually after molding, or to directly finish the surface of the mold. However, performing surface finishing on each part individually after molding complicates the process and reduces efficiency, while directly finishing the surface of the mold may result in an over-cut shape, making it unsuitable for machining components with complex shapes.

[0009] The present invention provides, for example, a novel structure for performing surface finishing on accessories included in a model plate or accessories that are part of a model.

[0010] means for solving problems

[0011] The present invention is, for example, a model plate comprising: a flow channel; and a specified accessory connected to the flow channel, the surface of which is roughened, wherein a mold for forming the specified accessory is manufactured by electrical discharge machining, and the discharge electrode of the electrical discharge machining is used to perform surface machining for roughening the surface of the specified accessory.

[0012] Additionally, the present invention includes, for example, a model component comprising a specified part whose surface has been roughened, wherein a mold for forming the specified part is manufactured by electrical discharge machining (EDM), and the discharge electrode of the EDM is used to perform surface machining for roughening the surface of the specified part.

[0013] In addition, the present invention provides, for example, a method for manufacturing a model plate having a flow channel and a specified accessory connected to the flow channel and having its surface roughened. The method for manufacturing the model plate includes the following steps: performing sandblasting on a discharge electrode to roughen the surface of the specified accessory; using the processed discharge electrode to manufacture a mold; and flowing synthetic resin into the manufactured mold to form the model plate.

[0014] Additionally, the present invention provides, for example, a method for manufacturing a model component, the model component comprising a specified fitting whose surface has been roughened, wherein the method comprises the following steps: performing sandblasting on a discharge electrode to roughen the surface of the specified fitting; using the processed discharge electrode to manufacture a mold; and flowing synthetic resin into the manufactured mold to form the model component.

[0015] Invention Effects

[0016] According to the present invention, for example, it is possible to provide a new structure for performing surface finishing on accessories included in a model plate or accessories that are model components. Attached Figure Description

[0017] Figure 1 This is a view showing the overall front view of a model panel according to one embodiment.

[0018] Figure 2 This is a flowchart illustrating the manufacturing process of a model panel (model component) according to one embodiment.

[0019] Figure 3 This is a diagram illustrating the detailed manufacturing process of one embodiment.

[0020] Figure 4 This is a diagram illustrating the detailed manufacturing process of one embodiment.

[0021] Figure 5This is a diagram illustrating a sandblasting process according to one embodiment.

[0022] Explanation of reference numerals in the attached figures

[0023] 100. Model plate; 101. Runner; 102. Gate; 103. Accessories (other accessories); 200. Accessories (specified accessories); 300. 3D data; 310. 330. Discharge electrode; 320. Jetting machine; 321. Processing material (sand); 400. Mold. Detailed Implementation

[0024] The embodiments will now be described in detail with reference to the accompanying drawings. Furthermore, the following embodiments do not limit the invention as defined in the claims, and not all combinations of features described in the embodiments are necessary for the invention. Any combination of two or more features described in the embodiments may be used. Additionally, identical or identical structures are labeled with the same reference numerals, and redundant descriptions are omitted.

[0025] <Structure of Model Panels (Flow Channels)>

[0026] Reference Figure 1 The structure of the model plate in this embodiment will be described. The arrows x, y, and z indicate the orientation of the model plate, which is formed by connecting multiple parts to a runner, at the top, left, and front, respectively. Here, a runner refers to a rod-shaped plastic section in a model toy, such as a plastic model, that connects multiple parts before assembly and is arranged in an enclosing manner. Sometimes, the entirety of the connected parts is also referred to as a runner. Here, when referring to the entire runner including multiple parts, it is called a "model plate". In this embodiment, an example of a model plate formed by connecting specified parts to a runner, which is characteristic of the present invention, will be described, but this is not intended to limit the present invention; it is also possible to provide a single part (hereinafter referred to as a model component) that is not connected to a runner.

[0027] Figure 1 The model plate 100 shown is connected to one or more fittings 103 via a gate 102 relative to the runner 101. Furthermore, the model plate 100 is formed in a state where fittings 200 with surface-finished properties are connected to the runner 101 in addition to the fittings 103 (other fittings). According to this embodiment, the surface-finished fittings do not refer to those that undergo surface finishing after the model plate 100 is formed, but rather to those that have undergone surface finishing at the time of forming.

[0028] Specifically, accessory 200 is formed with its surface treated in a predetermined manner, for example, it is provided as an accessory with a rough surface. In other words, accessory 200 is provided as an accessory with a rough tactile feel. On the other hand, accessory 103 is provided with a smooth surface, not a rough one. Thus, the model plate 100 of this embodiment is formed with accessories having different tactile surfaces connected to the runner 101. In addition, accessory 200 of this embodiment may also be formed with rough and smooth portions within its surface, as will be described in detail later.

[0029] The model plate 100 of this embodiment is manufactured by injection molding, which involves injecting synthetic resin raw materials into a mold using an injection device. The mold is configured to include a cavity (fixed side) and a core (movable side). The model plate 100 is manufactured by molding the synthetic resin raw materials by flowing into the cavity formed by the cavity and the core. Typically, the cavity abuts against the outer surface of the molded article, and the core abuts against the non-outer surface (back side). In this embodiment, at least one of the cavity mold and the core mold has been surface-finished. However, the present invention does not directly surface-finish the mold itself, but rather performs surface finishing on the discharge electrode used in mold manufacturing, and the surface finishing is reflected back onto the mold through the discharge processing of the discharge electrode. Details of the manufacturing process will be described later.

[0030] <Manufacturing Process (Flow)>

[0031] Reference Figure 2 The manufacturing process of the model plate (model component) of this embodiment will be described. The number following "S" indicates the step number. Here, the process of manufacturing the specified accessory, namely accessory 200, which has undergone surface finishing, will be mainly described.

[0032] First, in step S101, 3D data for each accessory and model part is created. The 3D data is created on an information processing device such as a personal computer. The 3D data includes design data for each accessory and configuration data for placing that accessory on the runner. The following explanation focuses primarily on the manufacturing of accessory 200.

[0033] In S102, a discharge electrode corresponding to the accessory 200 is manufactured according to the 3D data created in S101. The discharge electrode is formed into a shape for carving (melting) the workpiece, which serves as a mold, during electrical discharge machining. The discharge electrode is brought close to the mold, and current flows through it, thereby generating a discharge between the discharge electrode and the mold to perform grinding. Therefore, the discharge electrode is shaped like the accessory 200, with the shape of the mold reversed. Electrical discharge machining enables high-precision machining, and even harder raw materials such as molds can be machined. Furthermore, the discharge electrode does not contact the workpiece, thus avoiding consumption (wear) of the discharge electrode.

[0034] In S103, surface processing is performed on the discharge electrode manufactured in S102. In this embodiment, surface processing is a process of spraying treatment material onto the workpiece using compressed air from an ejector, but this is performed on the discharge electrode. The discharge electrode is made of a metal that is softer than the mold (harder metals, such as steel, superhard alloys, etc.) and is easy to process, such as copper or graphite. Sandblasting is a surface processing process in which a treatment material such as sand is sprayed onto the workpiece (mold) using compressed air from a compressor from an ejector to roughen its surface. As a result, the surface of the discharge electrode is roughened into a fine uneven shape, giving the surface of the discharge electrode a rough tactile feel.

[0035] Furthermore, in this embodiment, sandblasting is described as a surface finishing process, but this is not intended to limit the invention; shot peening, plasma processing, laser processing, etc., which can perform roughening treatments to roughen the surface, can also be used. In this embodiment, the surface roughened is formed with a gradient style of roughness (also called surface roughness or surface roughness degree). Gradient-style roughening treatment will be described later.

[0036] In S104, the metal is subjected to electrical discharge machining (EDM) using the discharge electrode processed in S103 to create a mold. During EDM, the discharge electrode is brought close to the mold, and discharge occurs between the electrode and the workpiece, thereby sculpting (melting). Then, in S105, accessory 200 (or model plate) is manufactured as a model component through injection molding, in which synthetic resin raw materials are injected into the mold using an injection device and shaped.

[0037] <Detailed Manufacturing Processes>

[0038] Reference Figure 3 and Figure 4 The detailed manufacturing process of accessory 200 is explained. Figure 3 This indicates the manufacturing process of the accessory 200 corresponding to S101 to S103 above. Figure 4 This indicates the manufacturing process of accessory 200 corresponding to S104 and S105 above.

[0039] like Figure 3 As shown, in S101, 3D data 300 for forming the part 200 is created. Next, in S102, the discharge electrode shown in 310 is created. The discharge electrode uses conductive copper or graphite, which can be easily processed. The processed portion of the upper part (black part) of the discharge electrode 310 in the figure is formed according to the 3D data 300 in the shape of the part 200. In this state, the surface of the discharge electrode 310 is smooth.

[0040] In step S103, the discharge electrode 310, which has a smooth surface, undergoes a surface treatment process called sandblasting. During sandblasting, the blasting machine 320 uses compressed air from a compressor to blast a treatment material 321, such as sand, onto the surface of the discharge electrode 310. As a result, the discharge electrode 310 is processed into a discharge electrode 330 with a roughened surface. Therefore, the surface of the discharge electrode 330 becomes roughened by grinding.

[0041] Next, as Figure 4 As shown, in S104, the surface-processed discharge electrode 330 is brought close to the mold and current flows through it, thus engraving the mold 400 by discharge. Figure 4 The image shows the state where the mold 400 has been etched using the discharge electrode 330. Thus, the mold 400 is etched in the reversed shape of the part 200. This prevents over-cutting compared to directly surface-processing the mold. Next, in S105, synthetic resin is injected into the mold 400 using an injection device (not shown) to form the part 200. The formed part 200, like the part 330, has a surface that has undergone surface processing (roughening).

[0042] <Sandblasting>

[0043] Reference Figure 5 The gradient style sandblasting process of this embodiment will be explained. Figure 5 This indicates the case where the discharge electrode 310 undergoes a roughening treatment based on sandblasting in S103.

[0044] In roughening processes such as sandblasting, the surface roughness of the object (discharge electrode 310) varies depending on the blasting pressure of the processing material (sand) 321 blasted by the blasting machine 320. In this embodiment, utilizing this principle, the discharge electrode 330 is fabricated by gradually reducing the blasting pressure while moving the blasting machine in the direction of the arrow in the figure, thereby gradually reducing the roughness. As a result, the discharge electrode 330 can have its roughness gradually varied in a predetermined direction (the direction of the arrow in the figure).

[0045] For example, such as Figure 5 As shown, the further to the right of the discharge electrode 330 in the diagram, the rougher the surface becomes; the further to the left, the smoother the surface becomes. Furthermore, while an example of moving the jetting machine 320 has been described here, it is also possible to control the position of the jetting machine 320 to be fixed while moving the discharge electrode 330, which serves as the workpiece. Additionally, while an example of reducing the jetting pressure of the processed material 321 has been described here, the intensity of the collision between the processed material 321 and the workpiece surface can also be varied by changing the distance between the jetting machine 320 and the workpiece.

[0046] According to this embodiment, the surface roughness can be varied within a single component, and this surface treatment is performed on the discharge electrode, not on components connected to pre-formed mold plates, thereby reducing the complexity of surface treatment. Furthermore, the surface treatment is performed on the discharge electrode, which is made of a soft material used for engraving the mold, rather than on the mold itself, allowing for easier processing and preventing excessive cutting during molding due to the flow of synthetic resin into the mold.

[0047] As explained above, the model plate of this embodiment includes a flow channel and a specified accessory (model part) connected to the flow channel and having its surface roughened. Furthermore, the mold for forming the specified accessory is manufactured by electrical discharge machining (EDM), and the surface of the discharge electrode used in the EDM is subjected to surface machining for roughening. According to this embodiment, the surface machining is performed on the discharge electrode used to manufacture the mold, rather than on the accessory or mold connected to the already formed model plate. This avoids the complexity of the machining process caused by surface machining each accessory after forming, and prevents the mold from becoming over-cut when its surface is directly machined. Thus, according to this embodiment, a new structure is provided for surface machining of accessories included in the model plate or accessories that are model parts.

[0048] This invention is not limited to the embodiments described above, and various modifications and alterations can be made within the scope of the invention's intent. For example, in the above embodiments, an example of using a single type of synthetic resin to mold the parts was described as different synthetic resins. However, this invention is not limited to this, and multiple different synthetic resins can be used. For example, raw materials with different softness (hardness), different textures, and different colors can also be used. Furthermore, in this embodiment, a model plate 100 including a single surface-finished part 200 was described, but the model plate of this invention may also include multiple surface-finished parts. Furthermore, in this embodiment, a method of manufacturing and providing the parts 200 while connected to the model plate 100 was described, but it is also possible to manufacture and provide only the parts 200. Furthermore, in this embodiment, an example of performing roughening treatment in a gradient style was described, but roughening treatment can also be performed by depicting arbitrary shapes such as stars, circles, or other shapes or markings.

[0049] <Summary of Implementation Methods>

[0050] The above embodiments disclose at least the following model plates, model components, and methods for manufacturing them. (1)

[0052] A model panel, wherein,

[0053] This model kit features:

[0054] Flow channels; and

[0055] The specified fittings, which connect to the flow channel, have surfaces that have been roughened.

[0056] The mold used to form the specified part is manufactured by electrical discharge machining.

[0057] The surface of the discharge electrode in the electrical discharge machining is subjected to surface processing for roughening. (2)

[0059] According to the model plate described in (1), the surface finishing is a process of spraying a material onto the object with compressed air using an ejector. (3)

[0061] According to the model plate described in (1) or (2), the surface roughness of the specified fitting varies in a gradient style. (4)

[0063] The model plate according to any one of (1) to (3), wherein the surface roughness of the specified fitting changes in a specified direction. (5)

[0065] A model component, wherein,

[0066] The model components include standard fittings with a roughened surface treatment.

[0067] The mold used to form the specified part is manufactured by electrical discharge machining.

[0068] The discharge electrode of the electrical discharge machining is used for surface machining to roughen the surface of the specified component. (6)

[0070] According to the model component described in (5), the surface finishing is a process in which a material is sprayed onto the object using compressed air from an ejector. (7)

[0072] According to the model component described in (5) or (6), the surface roughness of the specified accessory varies in a gradient style. (8)

[0074] The model component according to any one of (5) to (7), wherein the surface roughness of the specified fitting varies in a specified direction. (9)

[0076] A method for manufacturing a model plate, the model plate having a flow channel and specified fittings connected to the flow channel and having a roughened surface treatment, wherein...

[0077] The manufacturing method of this model plate includes the following steps:

[0078] The surface of the discharge electrode is roughened by sandblasting.

[0079] The processed discharge electrode is used to manufacture the mold; and

[0080] The model plate is formed by flowing synthetic resin into the mold it is manufactured. (10)

[0082] A method for manufacturing a model component, the model component comprising a specified fitting whose surface has been roughened, wherein,

[0083] The manufacturing method of this model component includes the following steps:

[0084] The surface of the discharge electrode is roughened by sandblasting.

[0085] The processed discharge electrode is used to manufacture the mold; and

[0086] The model part is formed by flowing synthetic resin into the mold that has been manufactured.

Claims

1. A model panel, wherein, This model kit features: Flow channels; and The specified fittings, which connect to the flow channel, have surfaces that have been roughened. The mold used to form the specified part is manufactured by electrical discharge machining. The discharge electrode of the electrical discharge machining is used for surface machining to roughen the surface of the specified component.

2. The model plate according to claim 1, wherein, The surface finishing process involves using an ejector to spray a material onto the object with compressed air.

3. The model plate according to claim 2, wherein, The surface roughness of the specified fittings varies in a gradient style.

4. The model plate according to claim 3, wherein, The surface roughness of the specified component changes in a specified direction.

5. A model component, wherein, The model components include standard fittings with a roughened surface treatment. The mold used to form the specified part is manufactured by electrical discharge machining. The discharge electrode of the electrical discharge machining is used for surface machining to roughen the surface of the specified component.

6. The model component according to claim 5, wherein, The surface finishing process involves using an ejector to spray a material onto the object with compressed air.

7. The model component according to claim 6, wherein, The surface roughness of the specified fittings varies in a gradient style.

8. The model component according to claim 7, wherein, The surface roughness of the specified component changes in a specified direction.

9. A method for manufacturing a model plate, the model plate having a flow channel and a specified accessory connected to the flow channel and having its surface roughened, wherein, The manufacturing method of this model plate includes the following steps: The discharge electrode is subjected to sandblasting for roughening the surface of the specified accessory; The processed discharge electrode is used to manufacture the mold; and The model plate is formed by flowing synthetic resin into the mold it is manufactured.

10. A method for manufacturing a model component, the model component comprising a specified fitting whose surface has been roughened, wherein, The manufacturing method of this model component includes the following steps: The discharge electrode is subjected to sandblasting for roughening the surface of the specified accessory; The processed discharge electrode is used to manufacture the mold; and The model part is formed by flowing synthetic resin into the mold that has been manufactured.

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