Model component and manufacturing method of model component

Abstract

To provide a model component that is graded with stable quality, and a method for manufacturing the model component.SOLUTION: The model component includes: a first layer formed of a first material of a first color; and a second layer formed so as to cover at least a part of the first layer, and made of a second material of a second color differing from the first color. The model component includes an area in which the second layer is formed such that a thickness of at least one portion is thinner than other portions.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a model part and a method for manufacturing a model part. [Background technology]

[0002] When coloring parts (also called components) of assembled models, such as plastic models (registered trademark), such as the face of a toy, each part is painted by hand or spray-painted using a mask with openings in the areas to be painted (see Patent Document 1). Also, a proposal has been made to automate painting by using a coloring device equipped with multiple printers and conveyors (see Patent Document 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Publication number 3-34226 [Patent Document 2] Japanese Patent Application Publication No. 8-47585 Summary of the Invention [Problem to be solved by the invention]

[0004] However, applying gradations in which the color gradually gets darker requires skill, and it is difficult to stabilize the quality. In addition, using a painting device for painting also requires additional capital investment and increases the size of the equipment.

[0005] Therefore, an object of the present invention is to provide a model component having a gradation of stable quality and a manufacturing method thereof. [Means for solving the problem]

[0006] To solve the above problems, the present invention provides a model part, a first layer formed of a first material of a first color; a second layer formed to cover at least a portion of the first layer, the second layer being made of a second material of a second color different from the first color; A model part having The second layer is characterized by including at least a portion of a region formed to be thinner than other portions. Effect of the Invention

[0007] According to the present invention, it is possible to provide a model component having a gradation of stable quality and a manufacturing method thereof. [Brief description of the drawings]

[0008] [Figure 1] 4 is a flowchart illustrating an example of a method for manufacturing a model part according to an embodiment of the invention. [Diagram 2] 1A to 1C are diagrams for explaining the structure of a model part corresponding to an embodiment of the present invention. [Diagram 3] FIG. 2 is a diagram for explaining a cross-sectional structure of a model part corresponding to an embodiment of the present invention. [Figure 4] 1A to 1C are diagrams for explaining a molded product produced according to a manufacturing method for a model part corresponding to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, exemplary embodiments of the invention will be described with reference to the drawings. In each drawing, the same reference numerals indicate the same elements. In each drawing, the up, down, left and right directions on the paper surface will be used in the description in the text as the up, down, left and right directions of the parts (or components) in this embodiment. In the embodiment described below, the present invention will be exemplified by polystyrene as a molding material, but is not limited to this, and does not exclude the use of other materials (polyethylene, thermoplastic resins such as ABS, thermosetting resins, metals, etc.).

[0010] First, a method for manufacturing a model part according to an embodiment of the present invention will be described with reference to the flow chart of FIG. 1. In S101, primary molding is performed to form a primary molding layer that constitutes the skeleton of the model part. Reinforced polystyrene (KPS) can be used as the molding material (raw material) of the primary molding layer. Next, in S102, secondary molding is performed to form a secondary molding layer on the upper side of the primary molding layer so as to cover the primary molding layer. For example, general-purpose polystyrene (GPPS) or high impact polystyrene (HIPS) can be used as the molding material of the secondary molding layer. In the following S103, tertiary molding is performed to form a tertiary molding layer on the upper side of the secondary molding layer so as to cover the secondary molding layer. The molding material of the tertiary molding layer can be KPS, which is the same as that of the primary molding layer. The tertiary molding layer forms the outer surface of the model part, but its thickness differs in parts, and the parts that are formed thin are formed thin enough that the color of the secondary molding layer formed below them can be seen through.

[0011] In the above process, the molding materials constituting the primary molding layer and the tertiary molding layer are the same in type and color. On the other hand, the molding material of the secondary molding layer is at least different in color from the molding materials of the primary molding layer and the tertiary molding layer. The secondary molding layer can be a color with a higher concentration than the primary molding layer and the tertiary molding layer. For example, when the model parts constitute a part of the face or body of a doll, the tertiary molding layer constituting the surface is skin color, while the secondary molding layer can be a dark skin color, a dark orange color, a dark pink color, or the like. The color of the tertiary molding layer and the color of the secondary molding layer may be the same color, or may be similar or opposite colors. In this embodiment, the tertiary molding layer and the secondary molding layer are formed with molding materials of different colors in this way, and the tertiary molding layer is formed thinly on top of it, so that the secondary molding layer with a different color underneath can be seen through, thereby making it possible to express a gradation.

[0012] In addition, the molding material of each molding layer can be a common material because the primary molding layer, secondary molding layer, and tertiary molding layer are bonded together and integrated. In the above example, although KPS, GPPS, and HIPS have different properties, a common material, polystyrene, is used. Other than polystyrene, for example, ABS resin or polyethylene (PE) may be used in common. Also, materials of different materials may be used for some layers.

[0013] The manufacturing method of the model part consisting of the above three molding steps can be carried out, for example, by using a multi-color molding device. In each molding step, a molding die corresponding to that step is used. Specifically, molding material is poured into the runner groove of the mold or the molding space (cavity) for molding each part to form a molded product, and after cooling, the molded product is removed from the mold. The molded products produced in the primary molding and secondary molding are attached to the mold of the next molding step, respectively, and secondary molding or tertiary molding is carried out. The molding method using a multi-color molding device itself is well known, so a more detailed explanation is omitted.

[0014] FIG. 2 is a diagram for explaining an example of the structure of a model part manufactured according to the manufacturing method of FIG. 1. FIG. 2(A) is a diagram showing an example of a model part 200 as a part of the body of a doll toy, manufactured by a three-stage molding process corresponding to this embodiment. FIG. 2(B) is a separation diagram of the model part 200 separated from the primary molding layer to the tertiary molding layer. As shown in FIG. 2(B), the primary molding layer 201 forms the skeleton part of the body. This skeleton has a comb-like or lattice-like structure including gaps between the members, but this structure is merely an example, and the skeleton may be structured so that the molding material is filled without gaps throughout the skeleton.

[0015] The secondary molding layer 202 is formed so as to cover the primary molding layer 201, and has an uneven surface which adjusts the thickness of the tertiary molding layer 203. The tertiary molding layer 203 is a molding layer which forms the surface of the model, and has a surface according to the desired external shape of the model. Since the model part 200 is part of the body of a doll toy, the surface shape of the tertiary molding layer expresses the lines of the abdominal muscles, the narrow waist, and the like.

[0016] Comparing the secondary molding layer 202 and the tertiary molding layer 203, the secondary molding layer 202 is configured to include a portion that is similar to the tertiary molding layer 203 (a reduced shape of the tertiary molding layer 203) and a portion that is not similar. The similarly shaped portion of the secondary molding layer 202 maintains the thickness of the tertiary molding layer 203 at a predetermined value. On the other hand, the non-similarly shaped portion is raised (forms a convex shape) more than the similarly shaped portion, and this results in the tertiary molding layer 203 being formed thinner than the predetermined value. Here, the predetermined value corresponds to the thinnest thickness of the tertiary molding layer that is transparent through the tertiary molding layer and the color of the secondary molding layer is not visible from the outside.

[0017] Next, the cross-sectional structure of the model part 200 corresponding to this embodiment will be described. FIG. 3(A) is a cross-sectional view showing an example of the AB cross section of the model part 200 in FIG. 2(A). As shown in the cross-sectional view of FIG. 3(A), it can be seen that the thickness of the tertiary molding layer 203 constituting the outermost surface of the model part 200 varies depending on the location of the model part 200. For example, comparing the thicknesses D1, D2, and D3, D1>D2≒D3. Here, D1 has the thinnest thickness (corresponding to the above-mentioned predetermined thickness) in the area where the secondary molding layer 202 cannot be seen through the surface of the tertiary molding layer 203. Also, D2 and D3 each have the thickness of the thinnest part in the area where the secondary molding layer 202 can be seen through the surface of the tertiary molding layer 203. D2 and D3 may be thinner than the predetermined thickness of D1.

[0018] In this embodiment, the values ​​of D1, D2, and D3 can be set as D1=d1 (for example, 1 mm) and D2=D3=d2 (for example, 0.5 mm), respectively. However, this is merely an example, and the values ​​of d1 and d2 may be made smaller or larger depending on the properties (transparency) of the material used. Alternatively, if it is desired to change the transparency of the base depending on the location, the thinnest value within the region may be set to a different value. For example, D2 may be 0.5 mm, and D3 may be 0.7 mm.

[0019] By forming the tertiary molding layer 203 partially thin in this manner, it becomes possible to observe the color of the secondary molding layer 202 located inside through the tertiary molding layer 203 from the outside of the model part 200. Fig. 3(B) is a diagram for explaining a case where the color of the secondary molding layer 202 can be observed from the outside of the model part 200 through the tertiary molding layer 203. As shown in Fig. 3(B), the transparent region 204 is formed at a position where the tertiary molding layer 203 is formed thin.

[0020] At this time, as the thickness of the tertiary molding layer 203 changes from the thinnest value d2 to d1 at which the base is no longer visible, the transparent area 204 changes from the darkest at the thinnest value, where the color of the base secondary molding layer 202 is visible, to gradually lighter in color and transitioning to the color of the tertiary molding layer 203 itself, allowing the observer to observe a gradation on the surface of the model part 200.

[0021] The appearance of the gradation can be made different by the difference in the way of changing from d2 to d1. For example, the way of changing from a dark color to a light color differs depending on whether the degree of change in thickness is made steep or gradual, so that different gradation expressions can be realized. For example, if you want to produce a dark color partially, you can make the change from d2 to d1 steep. On the other hand, if you want to transition from a dark color to a light color through a light color to the material color of the tertiary molding layer 203, you can make the change from d2 to d1 gentle. For example, in a circular area centered at a position where the thickness is d2, if you assume a situation where the thickness increases in the radial direction from the center and the thickness becomes d1 at a position of radius r from the center, if you increase the radius r, the change will be gentle, and if you decrease the radius r, the change will be steep.

[0022] In addition, while the value of d1 is fixed for the same molding material, the value of d2 can be variable, so the value of d2 may be changed according to the aspect of the gradation to be expressed. In the area to which gradation is to be added, if it is acceptable for the color to be expressed to be lighter than the darkest value, for example, the value of d2 can be set to 0.7 millimeters instead of 0.5 millimeters.

[0023] Next, referring to Fig. 4, the structure of a molded product molded by molding the primary to tertiary molding layers in order according to the molding method of Fig. 1 corresponding to this embodiment will be described. Fig. 4(A) is a diagram showing an example of a molded product 400 molded by primary molding. Fig. 4(B) is a diagram showing an example of a molded product 410 molded by secondary molding. Fig. 4(C) is a diagram showing an example of a molded product 420 molded by tertiary molding.

[0024] In the primary molding of S101 in FIG. 1, a molded product 400 is first produced. The molded product 400 is composed of a main runner 401, a sub-runner 402, and a part 403. The molded product 400 is made of reinforced polystyrene (KPS). The main runner 401 is formed so as to surround the periphery of the part 403, and the part 201 is fixed to the main runner 401 by being connected to the main runner 401 via the sub-runner 402. The main runner 401 and the sub-runner 402 correspond to grooves for injecting a molding material into a cavity corresponding to the part 403 in a first mold (not shown) (usually consisting of a male mold and a female mold). In the primary molding of S101, the molding material (KPS) is injected from the main runner groove of the first mold through the sub-runner groove into the cavity corresponding to the part 403, and the molding material is filled into all of the cavity, the main runner groove, and the sub-runner groove, and then cooled to produce the molded product 400.

[0025] Next, in the secondary molding of S102, a molded product 410 is produced. The molded product 410 is formed by covering at least a part of the molded product 400 with general purpose polystyrene (GPPS) or high impact polystyrene (HIPS). The molded product 410 is composed of a main runner 411, a sub-runner 412, and a part 413 in addition to the molded product 400. In this embodiment, the part 413 is formed by forming GPPS or HPPS on the surface of the part 403 from the main runner 411 via the sub-runner 412. The main runner 411 is fixed to the main runner 401 by connecting it to the sub-runner 402. Also, the part 413 is fixed to the main runner 401 via the main runner 411 by connecting it to the main runner 411 via the sub-runner 412.

[0026] Like main runner 401, main runner 411 and sub runner 412 correspond to grooves for flowing molding material into a cavity in a second mold (not shown) corresponding to part 413. In the secondary molding of S102, after molded product 400 is fixed in the second mold, molding material (GPPS or HIPS) is flowed from the main runner groove of the second mold through the sub runner groove into the cavity corresponding to part 413, filling the cavity, main runner groove, and sub runner groove with the molding material, and then cooling to produce molded product 410.

[0027] When performing secondary molding, the runner grooves are arranged only on the top and bottom of the part 413. This is for the following reasons. First, the part 413 is a part of the doll's torso, and the top and bottom parts are configured to be connected to other parts. Therefore, the top and bottom surfaces that correspond to the connecting surfaces are not exposed on the surface of the finished doll toy. In contrast, the side is the doll's torso itself, and will be exposed on the surface of the finished doll toy. At that time, if the connecting part with the sub-runner remains on the side, it will affect the appearance of the finished product. Therefore, when molding the molded product 410 by secondary molding, the runner grooves are arranged so that the molding material is supplied from a direction that does not affect the appearance of the finished product.

[0028] Next, in the tertiary molding in S103, molded product 420 is produced. Molded product 420 is formed by covering at least a part of molded product 410 with KPS. In addition to molded product 410, molded product 420 is composed of main runner 421, sub runner 422, and part 423. The surface of molded product 420 will be covered with KPS, but it is sufficient that at least the part exposed to the surface in the completed doll toy is covered with KPS, and it is not necessary that the entire molded product 420 is covered with KPS.

[0029] The main runner 421 is formed so as to surround the periphery of the part 423. In FIG. 4(C), the main runner 421 surrounds the periphery, but the main runner 421 may be provided only on the left and right sides. The part 423 is connected to the main runner 421 via the secondary runner 422. In FIG. 4(C), since the molded product 420 is viewed from the front side, there are some parts where the connection between the secondary runner 422 and the part 423 is hidden by the secondary runner 402 and not shown, but in such parts, the secondary runner 422 and the part 423 are connected on the back side of the secondary runner 402. The secondary runner 422 is also connected to the main runner 401 or the secondary runner 402, and the part 423 is fixed to the main runner 401 by this connection.

[0030] Like main runner 401, main runner 421 and sub runner 422 correspond to grooves for flowing molding material (KPS) into a cavity in a third mold (not shown) corresponding to part 423. In the tertiary molding of S103, after molded product 410 is fixed in the third mold, molding material is flowed from the main runner groove of the third mold through the sub runner groove into the cavity corresponding to part 423, filling the cavity, main runner groove, and sub runner groove with molding material, and then cooling is performed to produce molded product 420.

[0031] In this way, the molded product 420 can be molded. As shown in Fig. 4(C), all the parts connected to the side of the molded product 420 are KPS sub-runners, and GPPS or HPPS sub-runners are not present on the side, only on the top and bottom. Therefore, no traces of connections to the GPPS or HPPS runners remain on the surface of the body of the finished doll toy.

[0032] In the above embodiment, a method has been described in which a part corresponding to the skeleton of a part is formed by primary molding, and then secondary and tertiary molding are performed. However, the embodiment of the invention is not limited to this procedure. For example, for a portion where it is not necessary to create a skeleton, the primary molding may be omitted and the process may start with secondary molding.

[0033] It is considered necessary to prepare a skeleton when preparing a part that does not allow the secondary molding material to be exposed on the surface, such as the torso described in the above embodiment. For example, in the case of a doll toy, parts such as the torso, arms, and legs are expected to have their surfaces exposed, so a skeleton is prepared for such parts to ensure that they are fixed to the runner. If a skeleton is not prepared for such parts, the main runner and the sub-runner are formed only by the secondary molding layer prepared in the secondary molding, and the parts before the tertiary molding are connected to the main runner only by the sub-runner prepared in the secondary molding. The secondary molding layer has a weak connection to the main runner because the injection direction of the molding material is limited so that the connection part of the runner is not exposed on the surface of the doll toy, and there is a possibility that it cannot withstand the injection pressure when molding the tertiary molding material. Also, if a skeleton is not prepared, the parts are connected to the left and right directions of the main runner by the sub-runner prepared in the tertiary molding. In this case, the tertiary molding layer produced in the tertiary molding is thin, and the connection part is made as thin as possible so that no connection trace remains on the surface of the part, so the strength of the connection part between the part and the sub-runner is relatively weak, making it difficult to reliably fix the molded product to the runner. In contrast, when the skeleton is produced in the primary molding, the connection part between the part and the sub-runner penetrates the secondary molding layer and the tertiary molding layer to ensure the connection of the part, so the strength of the connection part can be increased. In this case, if the molding materials constituting the primary molding layer and the tertiary molding layer are the same color as in this embodiment, even if the connection part between the skeleton part formed in the primary molding and the sub-runner penetrates the tertiary molding layer, it will be difficult to notice because it is the same color, which is preferable in terms of improving the appearance of the finished product.

[0034] For the above reasons, it is desirable to perform primary molding for parts that should avoid exposing the secondary molding layer on the surface of the finished product. On the other hand, for parts that are exposed on the surface but are covered and hidden by other parts and are not ultimately exposed, such as the face of a doll toy, the ends can be hidden by hair parts, so primary molding may be omitted and secondary molding may be started. Also, even for arms and torso, if they include parts that are not exposed on the surface by separately attaching ornaments, it is possible to ensure connection with the runner at the parts hidden by the ornaments, so primary molding may be omitted.

[0035] In addition, although the case where the color of the material used in the secondary molding is one color has been described, materials of multiple colors may be used in layers. For example, in the above embodiment, the color of the tertiary molding layer forming the surface of the doll toy is flesh colored, and the color of the secondary molding layer is orange or pink, but a black layer may be further formed under the secondary molding layer to provide shading. In this case, the way of providing shading can be adjusted by adjusting the thickness of the layer in the same manner as in the above embodiment.

[0036] As described above, according to the present embodiment, it is possible to provide a model component having a stable quality gradation and a manufacturing method thereof.

Claims

1. a first layer formed of a first material of a first color; a second layer formed to cover at least a portion of the first layer, the second layer being made of a second material of a second color different from the first color; A model part having The second layer includes a region having at least a portion thinner than the other portion. A model part characterized by:

2. 2. The model part of claim 1, wherein the density of said first color is greater than the density of said second color.

3. 3. The model part according to claim 1, wherein the first color and the second color are colors that are in a similar color family, a similar color family, or an opposite color family.

4. 4. The model part according to claim 1, wherein the region is formed to include a portion thinner than a first thickness at which the first color is transmitted through the second material and becomes visible from outside the model part.

5. 5. The model part of claim 4, wherein the second layer is formed to transition from a second thickness less than the first thickness to the first thickness in the region.

6. 6. The model part of claim 5, wherein the second thickness is half the thickness of the first thickness.

7. 7. A model part according to any one of claims 1 to 6, further comprising a third layer of said second material covered by said first layer.

8. The model part according to claim 7, characterized in that the second layer and the third layer are connected to a runner for fixing the model part on a surface that constitutes the appearance of the completed product when the model part is combined with other model parts to form the completed product.

9. 9. The model part according to claim 8, wherein the first layer is connected to a runner on a surface that does not form an external appearance of the finished product when the model part forms the finished product.

10. A method for manufacturing a model part, comprising the steps of: A first step of forming a first layer using a first material of a first color; a second step of molding 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; Including, A manufacturing method, characterized in that in the second step, the second layer is shaped to include an area in which at least a portion is formed thinner than other portions.

11. a third step of forming a third layer of the second material before the first step; In the first step, the first layer is molded to cover the third layer; In the first step, the first material is provided from a direction corresponding to a surface of the model component that does not form an appearance of the finished product when the model component is combined with another model component to form the finished product; In the second and third steps, the second material is provided from a direction including a direction corresponding to a face of the model part that constitutes the appearance of the finished product when the model part is combined with another model part to constitute the finished product. The method according to claim 10 .

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