Model element body and manufacturing method thereof

Abstract

To provide a new model element body formed by combining different materials, and to provide a method for manufacturing it.SOLUTION: A model element body comprises: multiple runners formed from synthetic resins having different colors; and multiple parts connected to the multiple runners. The multiple parts include: a first part formed from a synthetic resin in a single color; and a second part formed by combining synthetic resins in multiple colors.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] Model toys use multiple types of parts, each made from a different synthetic resin. This allows for the creation of a model toy that combines multiple parts of different colors, for example. These parts are formed as a model element by connecting multiple parts to a runner, and each part is removed from the runner when assembling.

[0003] The above-mentioned model element is manufactured by pouring synthetic resin into a mold and molding it. Such model elements include those molded using a single synthetic resin and those molded using multiple different synthetic resins. When molding a single model element using multiple different synthetic resins, it is possible to form a single model element including parts of different colors. Patent Document 1 proposes a model element having multiple runners that group together synthetic resin model components of the same synthetic resin. Patent Document 2 proposes a multi-color molding device that removes a molded product molded in one mold and transfers it to the next mold, where it is wrapped around and insert-molded to form a single completed multi-color molded product. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Publication number 06-7745 [Patent Document 2] Special Publication No. 07-102590 Summary of the Invention [Problem to be solved by the invention]

[0005] The above-mentioned conventional technology allows for the creation of multicolored model elements, and even allows for the creation of multiple colors in a single part by using insert or rotational molding. However, insert or rotational molding requires changing molds for multiple molding processes, such as primary molding and secondary molding, which requires considerable effort.

[0006] The present invention provides, for example, a novel model element formed by combining different materials, and a method for manufacturing the same. [Means for solving the problem]

[0007] The present invention is characterized in that, for example, a model element includes a plurality of runners formed of synthetic resins of different colors and a plurality of parts connected to the plurality of runners, the plurality of parts including a first part formed of a single-color synthetic resin and a second part formed by combining synthetic resins of multiple colors.

[0008] The present invention also provides a method for manufacturing a model element that includes, for example, a first part formed of a single-color synthetic resin and a second part formed by combining multiple-color synthetic resins, the method including a primary molding process in which synthetic resin of the first color is injected into a mold to form it, a release process in which a stopper that fixes part of the mold is released, and a secondary molding process in which synthetic resin of a second color different from the first color is injected into the mold to form it, and the injection pressure of the synthetic resin of the second color in the secondary molding process moves part of the mold in a predetermined direction, causing the synthetic resin of the second color to flow into a gap created thereby to form the second part. [Effects of the Invention]

[0009] According to the present invention, for example, it is possible to provide a novel model element formed by combining different materials, and a method for manufacturing the same. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 2 is a diagram showing the entire front surface of a model element according to one embodiment. [Figure 2] FIG. 1 is a perspective view showing a multicolor part according to an embodiment. [Figure 3] 1A to 1C are diagrams illustrating a manufacturing procedure for a multicolor part according to an embodiment. [Figure 4] FIG. 10 is a diagram showing a stopper for fixing a part of a mold according to an embodiment. [Figure 5] FIG. 10 is a cross-sectional view of a multicolor part according to an embodiment. [Figure 6] FIG. 2 is a cross-sectional view of a movable piece according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, the embodiments will be described in detail with reference to the accompanying drawings. Note that the following embodiments do not limit the scope of the invention as claimed, and not all combinations of features described in the embodiments are necessarily essential to the invention. Two or more of the features described in the embodiments may be arbitrarily combined. Furthermore, the same reference numerals are used for the same or similar components, and redundant explanations will be omitted.

[0012] <Model base (runner) configuration> Next, referring to FIG. 1, an example of the configuration of a model element according to this embodiment will be described. The x, y, and z arrows respectively indicate the upward, leftward, and forward directions of a model element in which multiple parts are connected to a runner. Here, a runner refers to a rod-shaped plastic section in a toy model such as a plastic model to which multiple parts are connected before assembly and arranged in a surrounding manner. The runner may also refer to the entirety, including the multiple connected parts. Here, when referring to the entire runner including the multiple parts, it is referred to as a "model element."

[0013] The model element 100 shown in FIG. 1 is a multi-color molded model element. Here, a model element molded in multiple colors using synthetic resins of two colors will be described as an example. However, this is not intended to limit the present invention, and multiple colors may be molded using synthetic resin materials of even more different colors. The model element 100 is composed of a first portion 110 molded from a synthetic resin of a first color, a second portion 120 molded from a synthetic resin of a second color, and a third portion 130 molded from a synthetic resin of two colors. In FIG. 1, the portion molded from the synthetic resin of the first color is shown shaded, while the portion molded from the synthetic resin of the second color is not. Thus, according to this embodiment, in one model element, in addition to a first part formed from a synthetic resin material of a single color, a second part formed by combining synthetic resins of multiple colors is formed in a portion of the model element 100.

[0014] Furthermore, the model element 100 according to this embodiment is manufactured by injection molding, in which a synthetic resin material is injected into a mold by an injection device to form the model element 100. The mold includes a cavity (fixed side) and a core (movable side), and the model element 100 is manufactured by pouring a synthetic resin material into the hollow space between the cavity and the core to form the model element 100. Typically, the cavity abuts the exterior surface of the molded product, and the core abuts the non-exterior surface (rear surface). In this embodiment, core-back molding, in which a portion of the core mold is moved after primary molding to perform secondary molding, is described. However, this does not limit the present invention, and the present invention can also be applied to cavity-back molding, in which a portion of the cavity mold is moved after primary molding to perform secondary molding.

[0015] The model element 100 has a runner 101, gate 102, and part 103 molded from a synthetic resin of a first color in the first portion 110, and a runner 104, gate 105, and part 106 molded from a synthetic resin of a second color in the second portion 120. Parts 103 and 106 correspond to the first part molded from a synthetic resin of a single color. Meanwhile, the model element 100 has a multicolor part 200 in the third portion 130 formed by combining a synthetic resin of the first color with a synthetic resin of a second color that is different from the synthetic resin of the first color. The multicolor part 200 corresponds to the second part.

[0016] The model base 100 is manufactured by injecting a first color synthetic resin (first synthetic resin) into a mold from an injection device (not shown) to perform primary molding. After the injected resin solidifies, a second color synthetic resin (second synthetic resin) is injected from the injection device to perform secondary molding. In the case of a multicolor part 200, if different synthetic resins are poured into one part, the first synthetic resin fills that part, preventing the second synthetic resin from flowing in. However, according to this embodiment, after the first synthetic resin solidifies, a portion (movable piece) of the mold on the cavity or core side that molds the part is moved to create a gap, and a second, different synthetic resin is poured into that gap. This allows the mold to be used for primary and secondary molding without switching, enabling efficient molding of multicolor parts. Details of the manufacturing process will be described later.

[0017] In this embodiment, an example will be described in which a first color synthetic resin and a second color synthetic resin are used, but this is not intended to limit the scope of the present invention. For example, synthetic resins with different softness may be used, or parts with different hardness may be molded into a single part.

[0018] Furthermore, to form a single part in multiple colors, runners for the flow of different synthetic resins must be formed to match the shape of the part. However, the area for forming a single part is small, making it difficult to form multiple flow paths. Therefore, in this embodiment, submarine gates are used in some gates to ensure flow paths, as shown by 107 and 108. Here, a submarine gate (tunnel gate) is a tunnel-shaped gate formed in the mold that is simultaneously separated from the runner when the molded product is removed from the mold. Note that this is not intended to limit the present invention, and it is not necessary to use a submarine gate; other gates, such as a side gate or a jump gate, may also be used.

[0019] Furthermore, according to this embodiment, the model base 100 is molded using two colors of synthetic resin, and runners of different colors are connected at multiple locations 141-144. In this embodiment, the connection between runners of different colors (different resin materials) is achieved by injecting a first color synthetic resin (first synthetic resin) from an injection device (not shown) to perform primary molding, and after the poured resin has solidified to a certain extent, releasing a stopper member that blocks the flow of the first color synthetic resin (first synthetic resin) on the runner into the second color synthetic resin (second synthetic resin), and then injecting the second color synthetic resin (second synthetic resin) from the injection device to perform secondary molding. Here, the runners include a runner (referred to as a first runner) that is arranged to surround the part, and a runner (referred to as a second runner) that branches off from the first runner and leads to the part.

[0020] Here, we consider a case where only the first runner, which is arranged to surround the part, is connected to runners made of synthetic resins of other colors. In this case, because the connection points are limited, only simple color-coded parts can be molded in the multicolor part 200. For example, in the example of FIG. 1, the runner 101 made of synthetic resin of the first color is molded at the bottom of the figure, and the runner 104 made of synthetic resin of the second color is molded at the top of the figure. If a multicolor part is molded under this assumption, the first color synthetic resin is molded within the range that can flow in from the bottom of the figure, and the second color synthetic resin is molded within the range that can flow in from the top of the figure. This makes it extremely difficult to mold a part in which two colors of synthetic resin are intricately interwoven. To achieve this, the mold would need to be more precise and complex, which is not realistic in terms of manufacturing cost and effort.

[0021] On the other hand, according to this embodiment, second runners that branch off from the first runners and reach the parts are connected to each other, as shown by 143 and 144. This improves the degree of freedom when molding multicolored parts, and makes it possible to mold multicolored parts with complex patterns.

[0022] <Multicolored parts> An example of the configuration of a multicolor part according to this embodiment will be described with reference to Fig. 2. Note that the x, y, and z arrows indicate the upward, left, and forward directions of the multicolor part, respectively.

[0023] FIG. 2 shows a perspective view of a multicolored part 200 cut from the runner of the model base 100. The multicolored part 200 is composed of a first color synthetic resin 201 and a second color synthetic resin 202. This part 200 corresponds to the chest of a humanoid model toy. As shown in FIG. 2, the multicolored part 200 is formed by combining two colors of synthetic resin in a complex manner. Note that the multicolored part 200 is already formed in multiple colors when connected to the runner, as shown in FIG. 1, and is not formed by assembling parts of different colors.

[0024] As described in the Background Art section above, insert or rotational molding is typically used to form the multicolored part 200 when manufacturing the model element 100. However, insert or rotational molding involves removing a runner connected to one or more solidified parts from a mold after primary molding, transferring it, and then re-setting it in a different mold for secondary molding, where it is then molded. As such, insert or rotational molding is a very time-consuming manufacturing process and is unsuitable for mass production. Therefore, this embodiment describes a mechanism that enables the formation of the multicolored part 200 described above without changing molds. Below, a detailed description is given of the manufacturing process (core-back or cavity-back) for the model element 100 including the multicolored part 200 according to this embodiment.

[0025] <Manufacturing process for multi-colored parts> The manufacturing process for a multicolored part 200 according to this embodiment will be described with reference to FIG. 3. FIGS. 3(a) to 3(c) show perspective views of the multicolored part 200 attached to a mold during the manufacturing process, and FIGS. 3(d) to 3(f) show front views corresponding to FIGS. 3(a) to 3(c), respectively. In this embodiment, a model element including a multicolored part is manufactured by molding some parts using a core-back or cavity-back method that utilizes movable pieces. While the core-back method will be described here, the same applies to the cavity-back method, and in the case of the cavity-back method, the direction in which part of the mold moves is toward the cavity, opposite that of the core-back method.

[0026] 3(a) and 3(d) show the state of a multi-color part 200 after primary molding in the manufacturing process of the model base body 100. 201 indicates the state in which the first-color synthetic resin has solidified after primary molding. 210 indicates a frame for molding the multi-color part 200, which is part of the core-side mold. In primary molding, the first-color synthetic resin 201 flows into the gap formed between the frame 210 and the cabinet back-side mold (not shown) and is molded. Once the first-color synthetic resin 201 has solidified after primary molding, a second-color synthetic resin 202 is injected from an injection device (not shown).

[0027] 3(b) and 3(e) show the multicolor part 200 immediately after the second-color synthetic resin 202 has been injected. During secondary molding, when synthetic resin is injected from the injection device, the injection pressure causes the top 210 to move in a predetermined direction. In this embodiment, it moves downward (in the direction of the arrow) in the figure. This is because the top 210 is fixed in place by a stopper (described below) during primary molding, and by releasing the stopper before secondary molding, the top 210 moves due to the injection pressure. When the top 210 moves in the direction of the arrow, a gap 301 is formed between the top 210 and the first-color synthetic resin 201.

[0028] 3(c) and 3(f) show the state in which the synthetic resin 202 of the second color has flowed into the formed gap 301. Although not shown in FIG. 3, in reality, the synthetic resin 202 is sandwiched between molds on the cabinet back side, so the surface of the synthetic resin 202 of the second color that has flowed in is shaped as shown in the figures.

[0029] As shown in FIG. 3( f), the second-color synthetic resin 202 flows into the gap formed between the first-color synthetic resin 201 and the piece 210, forming a laminated structure of the first-color synthetic resin 201 and the second-color synthetic resin 202. Furthermore, where the first-color synthetic resin 201 and the second-color synthetic resin 202 overlap, the second-color synthetic resin 202 is formed on the side of the piece 210, which is part of the mold, in the predetermined direction as indicated by the circular dotted line area. For example, in the multicolor part 200 of FIG. 3, the upper side is the front side and the lower side is the back side. In this case, the second-color synthetic resin 202 is located below the first-color synthetic resin 201 regardless of its position, and is formed on the back side of the multicolor part 200 in the overlapping portion of the first-color synthetic resin 201 and the second synthetic resin 202. When a model element including multicolor parts is molded using the present invention, the above-described characteristics are exhibited. In this embodiment, the positional relationship described above is achieved because the top 210 moves downward, but the positional relationship differs depending on the direction in which the top moves.

[0030] <Mold configuration> The configuration of a portion of the mold according to this embodiment will be described with reference to Fig. 4. Fig. 4 shows a portion of the core-side mold. Note that, although an example in which a portion of the core-side mold is moved will be described here, this does not limit the present invention, and a portion of the cavity-side mold may also be moved.

[0031] Reference numerals 401 and 402 denote parts of the core-side mold, into which the movable piece 210 is fitted. Reference numeral 403 denotes a stopper for fixing the piece 210. By inserting the stopper 403 between 401 and 402 via an air cylinder (not shown), the piece 210 is restricted from moving downward in the drawing. Therefore, the piece 210 can be restricted from moving downward due to the injection pressure when synthetic resin is injected in the state shown in FIG.

[0032] On the other hand, when stopper 403 is removed from between 401 and 402, the fixation (movement restriction) of piece 210 is released. In this state, when synthetic resin is injected, piece 210 moves downward due to the injection pressure. It is possible to insert stoppers from multiple directions on the mold, in which case the movement of the movable piece can be restricted by each stopper, and multi-color parts can be molded in each location.

[0033] <Cross section of multicolored parts> A cross section of a multicolor part 200 according to this embodiment will be described with reference to Figure 5. As described above, in this embodiment, synthetic resin 201 of a first color is injected, molded, and solidified in the primary molding. Then, in the secondary molding, synthetic resin 202 of a second color is poured into the gap formed by moving movable top 210 in a predetermined direction using injection pressure. In other words, synthetic resin 202 of the second color flows into the gap formed and is molded.

[0034] Here, as shown in the dotted line area 500 in Figure 5, steps may be provided to give the part a three-dimensional appearance. Such step portions are relatively narrow (thin) areas, which can cause shorts (interruptions) in the filling of the synthetic resin during molding, resulting in insufficient molding defects. Therefore, in order to avoid the above-mentioned molding defects, the movable piece according to this embodiment is designed so that the step portions do not have a right-angle shape.

[0035] FIG. 6 shows a schematic cross section of a movable top. FIGS. 6(a) and 6(b) show cross sections of a movable top where short circuits are likely to occur. FIGS. 6(c) and 6(d) show cross sections of a movable top according to this embodiment. Also, 601 and 611 indicate parts of the mold on the cabinet side, and 602 and 612 indicate parts of the mold on the core side. In core-back or cabinet-back multi-color molding, the cabinet-side molds 601 and 611 or the core-side molds 602 and 612 move in the direction of the arrows after primary molding. Then, as shown by 603 and 613, the injected synthetic resin in secondary molding flows into the gap between them and is molded.

[0036] Here, molds 601 and 602 form step portions with a right-angled shape. In this case, as shown in region 604, the step portion becomes a narrow area after a part of the mold moves during secondary molding. Even if synthetic resin is poured in this state, the synthetic resin may clog region 604, resulting in molding defects.

[0037] On the other hand, the molds 611 and 612 according to this embodiment form the stepped portion using a slope at a predetermined angle without forming a right-angled portion. In this case, as shown in region 614, a wider area can be secured compared to when the stepped portion is formed at a right angle after a part of the mold moves during secondary molding. This makes it possible to avoid molding defects due to insufficient filling of the synthetic resin. Thus, according to this embodiment, the stepped portion formed in part of the mold is formed with a slope, thereby suppressing molding defects.

[0038] As described above, the model element according to this embodiment comprises a plurality of runners formed from synthetic resins of different colors, and a plurality of parts connected to the plurality of runners. The plurality of parts includes a first part formed from a single-color synthetic resin, and a second part formed by combining synthetic resins of multiple colors. This makes it possible to provide a novel model element molded from a combination of different materials without changing molds, and a method for manufacturing the same.

[0039] The present invention is not limited to the above-described embodiment, and various modifications and variations are possible within the scope of the invention. For example, in the above-described embodiment, an example was described in which multicolored parts were molded using synthetic resins of different colors as different synthetic resins. However, the present invention is not limited to this, and any synthetic resins of different materials may be used. For example, materials with different softness (hardness) or textures may be used.

[0040] <Summary of the embodiment> The above embodiment discloses at least the following model element and its manufacturing method. (1) A model element, Multiple runners made of synthetic resin of different colors, a plurality of parts connected to the plurality of runners; Equipped with The plurality of parts include: a first part formed of a single-color synthetic resin; and a second part formed by combining multiple colored synthetic resins. (2) The second part is formed by primary molding with a synthetic resin of a first color, followed by secondary molding with a synthetic resin of a second color in a gap created by moving a part of the mold in a predetermined direction. (3) The model element described in (2) is characterized in that the second part has the synthetic resin of the second color formed on the side of the specified direction to which part of the mold has moved in the area where the synthetic resin of the first color and the synthetic resin of the second color overlap. (4) The model element according to (2) or (3), wherein a part of the mold is fixed during the primary molding. (5) The model element described in (4) is characterized in that during the secondary molding, a part of the mold is released from its fixed state and moves in the specified direction due to the injection pressure of the second color synthetic resin. (6) The model element according to (5), wherein the step portion formed in the part of the mold is formed to include an inclination. (7) The model element according to any one of (2) to (6), wherein in the second part, the synthetic resin of the second color is molded through a submarine gate. (8) Among the plurality of runners, the runner formed of the synthetic resin of the first color and the runner formed of the synthetic resin of the second color are each formed of a first runner formed so as to surround at least one of the plurality of parts, and a second runner branching from the first runner to reach any one of the plurality of parts, A model element according to any one of (2) to (7), characterized in that a first runner formed from the synthetic resin of the first color and a first runner formed from the synthetic resin of the second color are connected, and a second runner formed from the synthetic resin of the first color and a second runner formed from the synthetic resin of the second color are connected. (9) The model element according to any one of (1) to (8), wherein a plurality of the second parts are formed. (10) The model element according to any one of (1) to (9), wherein the second part is formed by a core-back mold or a cavity-back mold. (11) The model element according to (10), wherein the second part is not formed by an insert mold or a rotation mold. (12) A method for manufacturing a model element including a first part formed of a single-color synthetic resin and a second part formed by combining multiple-color synthetic resins, a primary molding process in which a synthetic resin of a first color is injected into a mold; a release step of releasing a stopper that fixes a part of the mold; a secondary molding step of injecting a synthetic resin of a second color different from the first color into the mold; Including, a second part is molded by injecting the second color synthetic resin into a gap created by moving a part of the mold in a predetermined direction due to the injection pressure of the second color synthetic resin in the secondary molding process.

[0041] 100: Model body, 101, 104: Runner, 102, 105: Gate, 103, 106: Parts (single color parts), 107, 108: Submarine gate, 110: First part, 120: Second part, 130: Third part, 200: Multicolor parts, 201: First color synthetic resin, 202: Second color synthetic resin, 210: Piece

Claims

1. A model element, Multiple runners made of synthetic resin of different colors, a plurality of parts connected to the plurality of runners; Equipped with The plurality of parts include: a first part formed of a single-color synthetic resin; and a second part formed by combining multiple colored synthetic resins.

2. 2. The model element according to claim 1, wherein the second part is formed by primary molding with a synthetic resin of a first color, and then secondary molding with a synthetic resin of a second color in a gap created by moving a part of a mold in a predetermined direction.

3. 3. The model element according to claim 2, wherein in the second part, the synthetic resin of the second color is formed on the side of the mold to which the part of the mold has moved in the predetermined direction at the portion where the synthetic resin of the first color and the synthetic resin of the second color overlap.

4. 4. The model element according to claim 3, wherein a part of said mold is fixed during said primary molding.

5. 5. The model element according to claim 4, wherein, during the secondary molding, a part of the mold is released from fixation and moves in the predetermined direction due to the injection pressure of the second color synthetic resin.

6. 6. The model element according to claim 5, wherein the step portion formed in the part of the mold is formed to include an inclination.

7. 7. The model element according to claim 6, wherein the second color synthetic resin in the second part is molded through a submarine gate.

8. Among the plurality of runners, the runner formed of the synthetic resin of the first color and the runner formed of the synthetic resin of the second color are each formed of a first runner formed so as to surround at least one of the plurality of parts, and a second runner branching from the first runner to reach any one of the plurality of parts, 8. A model element according to claim 2, wherein a first runner formed from the synthetic resin of the first color and a first runner formed from the synthetic resin of the second color are connected, and a second runner formed from the synthetic resin of the first color and a second runner formed from the synthetic resin of the second color are connected.

9. 8. The model element according to claim 1, wherein a plurality of the second parts are formed.

10. 8. The model element according to claim 1, wherein the second part is formed by a core-back mold or a cavity-back mold.

11. 11. The model element according to claim 10, wherein the second part is not formed by an insert mold or a rotation mold.

12. A method for manufacturing a model element including a first part formed of a single-color synthetic resin and a second part formed by combining multiple-color synthetic resins, a primary molding step of injecting a synthetic resin of a first color into a mold; a release step of releasing a stopper that fixes a part of the mold; a secondary molding step of injecting a synthetic resin of a second color different from the first color into the mold; Including, a second part is molded by injecting the second color synthetic resin into a gap created by moving a part of the mold in a predetermined direction due to the injection pressure of the second color synthetic resin in the secondary molding process.

Images