Method for manufacturing mold and base plate

Abstract

To provide a method for efficiently manufacturing a molding die, and a base plate.SOLUTION: The method includes a step of inserting the second member 520 constituted by the plurality of insert members 530 into the 511a of the opening of the first member 510 to assemble the 500A of the base plate, a step of ejecting the shaping material onto the 500A of the base plate and stacking the layers to shape the stacked body serving as a part of the mold, a step of removing the insert member 530 from the 500A of the base plate in which the stacked body is shaped, and a step of performing cutting work on the stacked body, and in the step of assembling the 500A of the base plate, the plurality of insert members 530 are arranged and inserted to fill the 511a of the opening.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a molding die and a base plate. [Background technology]

[0002] Patent document 1 discloses a method for manufacturing a molding die that improves the adhesion strength between a base plate and a laminate by forming multiple through holes in the base plate and ejecting a molding material onto the base plate so that some of the molding material penetrates the through holes. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2023-159914 Summary of the Invention [Problem to be solved by the invention]

[0004] However, although the method described in Patent Document 1 improves the adhesion between the base plate and the laminate, it is difficult to remove the base plate and the laminate in the next manufacturing step, which results in poor processing efficiency and a long processing time. [Means for solving the problem]

[0005] The method for manufacturing a molding die is a method for manufacturing a molding die used in an injection molding apparatus, and includes the steps of assembling a base plate by inserting a second member composed of a plurality of nesting members into an opening of a first member, forming a laminate that becomes part of the molding die by ejecting a molding material onto the base plate and stacking layers, removing the second member from the base plate on which the laminate has been formed, and performing cutting processing on the laminate, and the step of assembling the base plate involves arranging and inserting the plurality of nesting members so as to fill the opening.

[0006] The base plate is a base plate on which the molding material used in the injection molding device is stacked, and has a first member and a second member, the first member having an opening, and the second member being composed of a plurality of nesting members arranged so as to fill the opening. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a schematic diagram showing the configuration of an injection molding device. [Figure 2] FIG. 2 is a perspective view showing the configuration of a flat screw. [Figure 3] FIG. [Figure 4] FIG. 1 is a perspective view showing a configuration of a three-dimensional modeling apparatus. [Figure 5] FIG. 3 is a cross-sectional view showing the configuration of a modeling unit. [Figure 6] FIG. 2 is a perspective view showing the configuration of a molding die including a base plate. [Figure 7] FIG. 7 is a cross-sectional view of the mold shown in FIG. 6 taken along the line AA. [Figure 8] FIG. 2 is a perspective view showing the configuration of a base plate. [Figure 9] FIG. 3 is a perspective view showing the configuration of a first member that constitutes the base plate. [Figure 10] FIG. 4 is a perspective view showing the configuration of an insert member that constitutes the second member. [Figure 11] FIG. [Figure 12] 1 is a flowchart showing a method for manufacturing a molding die. [Figure 13] FIG. [Figure 14] 4A to 4C are cross-sectional views showing a part of a method for manufacturing a molding die. [Figure 15] FIG. [Figure 16] 4A to 4C are cross-sectional views showing a part of a method for manufacturing a molding die. [Figure 17] 4A to 4C are cross-sectional views showing a part of a method for manufacturing a molding die. [Figure 18]FIG. [Figure 19] FIG. DETAILED DESCRIPTION OF THE INVENTION

[0008] The manufacturing method of the forming die 600 and the configuration of the base plate 500A will be described below with reference to the drawings. In the following drawings, three mutually perpendicular axes will be referred to as the X-axis, Y-axis, and Z-axis. The direction along the X-axis will be referred to as the "X-direction," the direction along the Y-axis will be referred to as the "Y-direction," and the direction along the Z-axis will be referred to as the "Z-direction." The direction of the arrow is the + direction, and the direction opposite to the + direction is referred to as the - direction. Note that a view from the +Z direction or the -Z direction is also referred to as a planar view or planar.

[0009] First, with reference to FIG. 1, the configuration of an injection molding apparatus 10 in which a molding die 600 is used will be described.

[0010] As shown in FIG. 1, the injection molding apparatus 10 includes a plasticizing unit 110, an injection control mechanism 120, a mold clamping unit 130, and a molding die 600.

[0011] The plasticizing device 110 includes a first flat screw 111 , a barrel 112 , a first heater 113 , and a first nozzle 114 .

[0012] The first flat screw 111 is housed in the housing portion 101. The first flat screw 111 is also called a scroll or a rotor. The first flat screw 111 is driven to rotate around a rotation axis RX within the housing portion 101 by a screw drive portion 115 that is composed of a drive motor and a reducer.

[0013] In this embodiment, the X direction is the direction along the rotation axis RX. An outflow hole 116 is formed in the center of the barrel 112. An injection cylinder 121, which will be described later, is connected to the outflow hole 116. A check valve 124 is provided in the outflow hole 116 upstream of the injection cylinder 121.

[0014] The injection control mechanism 120 includes an injection cylinder 121, a plunger 122, and a plunger driver 123. The injection control mechanism 120 has a function of injecting the plasticized material in the injection cylinder 121 into a cavity 551, which will be described later. The injection control mechanism 120 controls the injection amount of the plasticized material from the first nozzle 114.

[0015] The injection cylinder 121 is a substantially cylindrical member connected to the outlet hole 116 of the barrel 112, and has a plunger 122 therein. The plunger 122 slides inside the injection cylinder 121, and pressure-feeds the plasticized material in the injection cylinder 121 to the first nozzle 114 provided in the plasticizing device 110. The plunger 122 is driven by a plunger drive unit 123 constituted by a motor.

[0016] The molding die 600 comprises a movable die 500 and a fixed die 400. The movable die 500 and the fixed die 400 are disposed facing each other, with a cavity 551 between them that corresponds to the shape of the molded product. The movable die 500 and the fixed die 400 are formed with concave and convex shapes that define the cavity 551. The concave shape that defines the cavity 551 is also called a cavity portion, and the convex shape is also called a core portion.

[0017] The plasticized material flowing out from the outlet hole 116 of the barrel 112 is pressure-fed by the injection control mechanism 120 and injected into the cavity 551 from the first nozzle 114. Details of the movable mold 500 and the fixed mold 400 will be described later, but the movable mold 500 and the fixed mold 400 in this embodiment are resin molds including a laminate 550 in which the cavity 551 is formed, a base plate 500A, and a mold base 560.

[0018] Clamping device 130 is equipped with a mold drive unit 131 and has the function of opening and closing movable mold 500 and fixed mold 400. Clamping device 130 drives mold drive unit 131, which is made up of a motor, to rotate ball screw 132, which moves movable mold 500, which is coupled to ball screw 132, relative to fixed mold 400, thereby opening and closing molding mold 600. In other words, fixed mold 400 is stationary in injection molding apparatus 10, and movable mold 500 moves relative to stationary fixed mold 400, thereby opening and closing molding mold 600.

[0019] Movable mold 500 is provided with an ejection mechanism 407 for releasing the molded product from molding die 600. Ejection mechanism 407 has an ejector pin 408, a support plate 409, a support rod 406, a spring 411, an ejection plate 412, and a thrust bearing 413.

[0020] The ejector pin 408 is a rod-shaped member for pushing out the molded product molded in the cavity 551. The ejector pin 408 is provided so as to penetrate through the movable mold 500 and into the cavity 551. The support plate 409 is a plate member that supports the ejector pin 408. The ejector pin 408 is fixed to the support plate 409. The support rod 406 is fixed to the support plate 409, and is inserted into a through-hole 552 formed in the movable mold 500.

[0021] The spring 411 is disposed in the space between the movable mold 500 and the support plate 409, and is inserted into the support rod 406. During molding, the spring 411 biases the support plate 409 so that the head of the ejector pin 408 forms part of the wall surface of the cavity 551. The ejector plate 412 is fixed to the support plate 409. The thrust bearing 413 is attached to the ejector plate 412, and is provided so that the head of the ball screw 132 does not damage the ejector plate 412. Note that instead of the thrust bearing 413, a thrust sliding bearing or the like may be used.

[0022] Next, the configuration of the first flat screw 111 will be described with reference to FIG.

[0023] 2, the first flat screw 111 has a generally cylindrical shape with a height along the rotation axis RX that is smaller than its diameter. A spiral groove 202 is formed around a central portion 205 on a groove forming surface 201 of the first flat screw 111 that faces the barrel 112.

[0024] The grooves 202 communicate with a material inlet 203 formed on the side surface of the first flat screw 111. Material supplied from a material supply unit such as a hopper is supplied to the grooves 202 through the material inlet 203. The grooves 202 are formed by being separated by convex portions 204.

[0025] In this embodiment, an example is shown in which three grooves 202 are formed, but the number of grooves 202 may be one or two or more. Note that the groove 202 is not limited to a spiral shape, and may be a helical or involute curve shape, or may have a shape that extends in an arc from the center portion 205 to the outer periphery.

[0026] Next, the configuration of the barrel 112 will be described with reference to FIG.

[0027] 3, the barrel 112 has an opposing surface 212 that faces the groove-forming surface 201 of the first flat screw 111. An outflow hole 116 is formed in the center of the opposing surface 212. A plurality of guide grooves 211 are formed in the opposing surface 212, which are connected to the outflow hole 116 and extend spirally from the outflow hole 116 toward the outer periphery.

[0028] The material supplied to the groove 202 of the first flat screw 111 is plasticized between the first flat screw 111 and the barrel 112 by the rotation of the first flat screw 111 and the heating of the first heater 113, and flows along the groove 202 and the guide groove 211 by the rotation of the first flat screw 111, and is guided to the central portion 205 of the first flat screw 111. The material that has flowed into the central portion 205 is guided to the injection control mechanism 120 from an outlet hole 116 provided in the center of the barrel 112. The guide groove 211 does not necessarily have to be provided in the barrel 112. Furthermore, the guide groove 211 does not necessarily have to be connected to the outlet hole 116.

[0029] In this embodiment, "plasticization" is a concept that includes melting, and refers to changing from a solid to a fluid state. Specifically, in the case of a material that undergoes glass transition, plasticization refers to raising the temperature of the material to or above the glass transition point. In the case of a material that does not undergo glass transition, plasticization refers to raising the temperature of the material to or above the melting point.

[0030] Next, the configuration of the three-dimensional modeling apparatus 300 will be described with reference to FIGS.

[0031] 4, the three-dimensional modeling apparatus 300 stacks layers to form a laminated body 550 that will become a part of a molding die 600 used in the injection molding apparatus 10. The laminated body 550 is also called a molded part.

[0032] The three-dimensional modeling apparatus 300 includes a modeling unit 310, a cutting unit 320, a stage 330, a moving mechanism 340, and a control unit 350.

[0033] The control unit 350 is configured by a computer having one or more processors, a main memory device, and an input / output interface for inputting and outputting signals from and to the outside. The control unit 350 controls the operations of the modeling unit 310, the cutting unit 320, and the movement mechanism 340 by the processor executing programs and instructions loaded onto the main memory device. Note that the control unit 350 may be configured by a combination of multiple circuits instead of a computer.

[0034] Under the control of the control unit 350, the three-dimensional modeling device 300 ejects a modeling material 550A from a second nozzle 311 provided in the modeling unit 310 toward the stage 330, while driving the moving mechanism 340 to change the relative position between the second nozzle 311 and the stage 330, thereby modeling a laminate 550 on the stage 330.

[0035] Furthermore, under the control of the control unit 350, the three-dimensional modeling device 300 rotates the cutting tool 321 attached to the cutting unit 320 while driving the moving mechanism 340 to change the relative position between the cutting tool 321 and the stage 330, thereby cutting the laminate 550 stacked on the stage 330 with the cutting tool 321 to form a cavity 551.

[0036] As shown in FIG. 5, the modeling unit 310 includes a material supply unit 312 that is a material supply source, a plasticizing unit 313 that plasticizes the material to form a modeling material 550A, and a discharging unit 314 that discharges the modeling material.

[0037] The material supply unit 312 supplies raw materials for producing the modeling material 550A to the plasticizing unit 313. The material supply unit 312 is configured, for example, by a hopper that stores the raw materials. The material supply unit 312 is connected to the plasticizing unit 313 via a material supply path 315 connected below. The raw materials are input into the material supply unit 312 in the form of pellets, powder, or the like.

[0038] Examples of raw materials include materials whose main component is a resin such as COC (cyclic olefin copolymer), ABS (acrylonitrile butadiene styrene), POM (polyacetal), PA (polyamide) 66, PPS (polyphenylene sulfide), PEEK (polyether ether ketone), and PBI (polybenzimidazole). The term "main component" refers to the component that is the most prevalent in the material by mass, e.g., 50% by mass or more. In addition to the main component, the raw materials may also contain other components such as metals, ceramics, solvents, and binders.

[0039] The plasticizing unit 313 has a configuration similar to that of the plasticizing device 110 of the injection molding apparatus 10 shown in Figure 1. That is, the plasticizing unit 313 plasticizes the raw material using a second flat screw 316, a second barrel 317, and a second heater 309. The plasticizing unit 313 plasticizes the raw material supplied from the material supply unit 312 to generate a paste-like modeling material 550A that exhibits fluidity, and guides the paste-like modeling material 550A to the discharge unit 314.

[0040] The discharge unit 314 includes a second nozzle 311 that discharges the modeling material 550A generated by the plasticizing unit 313 toward the stage 330. The discharge unit 314 includes a discharge amount adjustment unit 318 that can adjust the amount of the modeling material 550A discharged from the second nozzle 311. In this embodiment, the discharge amount adjustment unit 318 is configured by a butterfly valve. The control unit 350 adjusts the amount of the modeling material 550A discharged by driving a valve driving unit 319 configured by a motor or the like to rotate the butterfly valve.

[0041] 4, the cutting unit 320 rotates a cutting tool 321 attached to the tip on the stage 330 side to cut the laminate 550 stacked on the stage 330. For example, a flat end mill or a ball end mill can be used as the cutting tool 321. The control unit 350 controls the movement mechanism 340 to change the relative position between the cutting tool 321 and the laminate 550 stacked on the stage 330, thereby controlling the cutting position.

[0042] The stage 330 is supported by a moving mechanism 340. In this embodiment, the moving mechanism 340 is configured as a three-axis positioner that moves the stage 330 along the X, Y, and Z directions relative to the modeling unit 310 and the cutting unit 320. In this embodiment, a base plate 500A that constitutes a part of the molding die 600 is removably fixed on the stage 330, and the laminate 550 is modeled on the base plate 500A.

[0043] Note that the moving mechanism 340 may move the modeling unit 310 and the cutting unit 320 relative to the stage 330 without moving the stage 330. Alternatively, the moving mechanism 340 may move both the stage 330 and the modeling unit 310 and the cutting unit 320. The moving mechanism 340 may have a function of tilting the stage 330 with respect to a horizontal plane, or may have a function of tilting the second nozzle 311 or the cutting tool 321.

[0044] Next, the configuration of the molding die 600 will be described with reference to FIGS.

[0045] 6, the base plate 500A has a first member 510 (see FIG. 9) and a second member 520 (see FIG. 8). The first member 510 and the second member 520 are made of, for example, a metal material. Note that the first member 510 and the second member 520 are not limited to metal, and may be made of a material such as glass or ceramic.

[0046] 9, an opening 511 is formed in the first member 510. Specifically, two rectangular openings 511a and 511b are formed in the first member 510. The two openings 511a and 511b are formed so that the second member 520 (see FIG. 8) can be disposed in them.

[0047] As shown in Fig. 8, the second member 520 is configured with a plurality of nesting members 530 in close contact with each other. In this embodiment, there are eight nesting members 530. As shown in Fig. 10, the nesting member 530 is provided with a plurality of first through holes 531. In this embodiment, five first through holes 531 are formed.

[0048] The first through-hole 531 has a straight shape with the same hole diameter from the first surface 530a of the insert member 530 on which the laminate 550 is formed to the second surface 530b opposite to the first surface 530a.

[0049] The eight nesting members 530 have the same outer shape and the same diameter of the first through holes 531. In this way, since the multiple nesting members 530 have the same shape and the same diameter of the first through holes 531, the openings 511a can be filled, in other words, assembled, without having to worry about the order in which the nesting members 530 are inserted into the openings 511a. Furthermore, since the nesting members 530 are the same, the nesting members 530 can be formed without increasing the number of steps.

[0050] 8, the longitudinal direction of nesting member 530, i.e., the Y direction, is the same as the longitudinal direction of base plate 500A, i.e., the direction along the Y direction. Since the longitudinal direction of nesting member 530 and the longitudinal direction of base plate 500A are aligned in this way, it is possible to reduce the gap between base plate 500A and multiple nesting members 530, and it is possible to prevent rattling between opening 511 and nesting members 530.

[0051] As shown in Figure 7, the first through hole 531 is used to increase the adhesion between the base plate 500A and the laminate 550 by allowing the molding material 550A, which is the material of the laminate 550, to penetrate into the first through hole 531 when the laminate 550 is formed on the base plate 500A, thereby preventing the laminate 550 from floating up from the base plate 500A.

[0052] In this way, since the first through-hole 531 is provided in the nesting member 530, it is possible to insert the molding material 550A into the first through-hole 531, thereby improving the anchor effect, i.e., the adhesive strength between the base plate 500A including the nesting member 530 and the stacked body 550. Note that a pin for pushing the product 700 out of the stacked body 550 may be disposed in the first through-hole 531.

[0053] 8, the first member 510 is provided with a plurality of second through holes 512 that function similarly to the first through holes 531. Specifically, the plurality of second through holes 512 are provided around the openings 511a and 511b of the first member 510. The diameter of the second through holes 512 is larger than the diameter of the first through holes 531. The larger the hole diameter, the more the modeling material 550A can enter, and the stronger the adhesion between the layered body 550 and the base plate 500A.

[0054] In this way, the diameter of second through hole 512 of first member 510 is larger than the diameter of first through hole 531 of nesting member 530, so it is possible to increase the adhesion between stacked body 550 and first member 510, in other words, the adhesion around nesting member 530. Therefore, compared to when the adhesion between nesting member 530 and stacked body 550 is high, it is possible to suppress warping of stacked body 550.

[0055] 11, internal thread portions 532 are provided on a second surface 530b of the insert member 530 opposite to a first surface 530a on which the laminate 550 is formed, i.e., the surface on the side that comes into contact with the support plate 540. In this embodiment, the insert member 530 has two internal thread portions 532.

[0056] In this way, the female thread portion 532 is formed in the insert member 530, and therefore, it can be used, for example, when inserting the insert member 530 into or removing it from the opening 511 of the first member 510.

[0057] As described above, the base plate 500A has a first member 510 and a second member 520, the first member 510 having an opening 511, and the second member 520 being composed of a plurality of nesting members 530, which are arranged so as to fill the opening 511 (see FIG. 8).

[0058] In this way, the layered body 550 is formed by stacking the modeling material 550A on the base plate 500A, which is formed by assembling a plurality of nesting members 530 arranged so as to fill the opening 511. Therefore, the adhesion between the layered body 550 and each nesting member 530 is lower than the adhesion between the layered body 550 and the second member 520 when, for example, the second member 520 is composed of a single member. Therefore, when removing the second member 520 from the base plate 500A, each nesting member 530 can be easily removed. In other words, the nesting members 530 can be easily removed from the base plate 500A. This allows the work to proceed to the next process quickly, improving processing efficiency. Furthermore, the processing time required can be reduced.

[0059] Next, a method for manufacturing movable mold 500, which is one of the methods for manufacturing molding mold 600, will be described with reference to FIGS.

[0060] 12, in step S11, the first member 510 and the second member 520 are combined to complete the base plate 500A. Specifically, as shown in Fig. 13, a plurality of nesting members 530 are arranged and inserted so as to fill the openings 511 of the first member 510. In this embodiment, the plurality of nesting members 530 are inserted into only one of the openings 511a.

[0061] Next, in step S12, laminated body 550 is formed. Specifically, as shown in Fig. 14, using three-dimensional printing apparatus 300, modeling material 550A is dispensed onto base plate 500A fixed on stage 330 to stack layers, thereby forming laminated body 550, which will become a part of molding die 600.

[0062] 14, in the three-dimensional modeling apparatus 300, a solid raw material is plasticized in the plasticizing section 313 (see FIG. 5) of the modeling unit 310 to generate a modeling material 550A. As shown in FIG. 4, the control section 350 discharges the modeling material 550A from the second nozzle 311 while changing the position of the second nozzle 311 relative to the stage 330 in a direction along the upper surface of the stage 330, while maintaining the distance between the stage 330 and the second nozzle 311. The modeling material 550A discharged from the second nozzle 311 is continuously deposited on the base plate 500A in the movement direction of the second nozzle 311, and a layer L is formed.

[0063] The control unit 350 repeatedly scans the second nozzle 311 to form multiple layers L. More specifically, after forming one layer L, the control unit 350 moves the position of the second nozzle 311 in the Z direction relative to the stage 330. Then, a layer L is stacked on top of the layers L that have been formed so far, thereby forming a stacked body 550.

[0064] 15, the base plate 500A has a plurality of through holes 512, 531 formed on the surface on which the layered body 550 is stacked. Therefore, when the second nozzle 311 moves across the through holes 512, 531 and ejects the modeling material 550A, part of the modeling material 550A enters the through holes 512, 531, and an anchor effect is exerted by the through holes 512, 531. Therefore, it is possible to prevent the layered body 550 from peeling off from the base plate 500A during modeling of the layered body 550.

[0065] Next, in step S13, the second member 520 is removed from the base plate 500A. Specifically, as shown in Fig. 16, the bolt member 533 is attached to the female thread portion 532 from the second surface 530b side of the insert member 530. The bolt member 533 has a male thread portion 534 formed therein that corresponds to the female thread portion 532.

[0066] Next, in step S14, the nesting members 530 are removed from the first member 510. Specifically, as shown in Fig. 17, one nesting member 530 is removed from the first member 510 by pulling the bolt member 533 attached to the nesting member 530. Thereafter, the remaining nesting members 530 are also removed from the first member 510, thereby completing the removal of the second member 520 from the base plate 500A.

[0067] In this way, bolt member 533 is joined to female thread portion 532, and insert member 530 is pulled together with bolt member 533 from base plate 500A, so insert member 530 can be relatively easily pulled out from base plate 500A. Therefore, compared to a case where bolt member 533 is not used, it is possible to improve manufacturing efficiency and shorten manufacturing time.

[0068] Furthermore, since the stacked body 550 is formed on the base plate 500A assembled by inserting multiple nesting members 530 into the openings 511 of the first member 510, the adhesion between the stacked body 550 and each nesting member 530 is lower than the adhesion between the stacked body 550 and the second member 520 when the second member 520 is composed of a single member. Therefore, when removing the second member 520 from the base plate 500A, each nesting member 530 can be easily removed. In other words, the nesting members 530 can be easily removed from the base plate 500A. This allows for a quick transition to the next cutting process, improving processing efficiency. Furthermore, the processing time required can be reduced.

[0069] Next, in step S15, cutting is performed. Specifically, as shown in Fig. 4, cutting is performed on the laminate 550 using a cutting unit 320. As shown in Fig. 18, by performing cutting, a concave cavity 551 is formed in the laminate 550. Note that a convex cavity may also be formed in the laminate 550. Furthermore, the number of cavities 551 is not limited to one, and two or more may be formed.

[0070] Note that, in the laminate 550, a through hole 552 for inserting the ejector pin 408 may be formed in the bottom of the cavity 551 using the cutting unit 320. Since the insert member 530 is removed from the base plate 500A in advance, the formation of the through hole 552 by the cutting unit 320 is not blocked by the insert member 530.

[0071] The cutting process may cut not only cavities 551 and through-holes 552 but also the surface and side surfaces of laminate 550. Furthermore, prior to the cutting process, it is not limited to removing all of nesting members 530 from base plate 500A, and only portions of nesting members 530 that will be affected by the cutting process may be removed.

[0072] In the next step, as shown in FIG. 19, base plate 500A on which laminate 550 has been formed is fitted into opening 561 of mold base 560. Mold base 560 is made of, for example, a metal material. Mold base 560 has, for example, a bottom. At this time, insert member 530 may be inserted into first member 510 constituting base plate 500A, or insert member 530 may remain removed. This completes movable mold 500, which is part of molding die 600. Molding die 600 manufactured as described above is attached to injection molding apparatus 10 (see FIG. 1) and used for injection molding.

[0073] As described above, the manufacturing method of the molding die 600 of this embodiment is a manufacturing method of the molding die 600 used in the injection molding apparatus 10, and includes the steps of assembling the base plate 500A by inserting the second member 520 composed of multiple nesting members 530 into the opening 511 of the first member 510, forming the laminate 550 that becomes part of the molding die 600 by ejecting the molding material 550A onto the base plate 500A and stacking layers L, removing the second member 520 from the base plate 500A on which the laminate 550 has been formed, and performing cutting processing on the laminate 550. The step of assembling the base plate 500A involves arranging and inserting multiple nesting members 530 so as to fill the opening 511.

[0074] According to this method, the stacked body 550 is formed on the base plate 500A assembled by inserting multiple nesting members 530 into the openings 511. Therefore, the adhesion between the stacked body 550 and each nesting member 530 is lower than the adhesion between the stacked body 550 and the second member 520 when the second member 520 is composed of a single member. Therefore, when removing the second member 520 from the base plate 500A, each nesting member 530 can be easily removed. In other words, the nesting members 530 are easily removed from the base plate 500A. In other words, the stacked body 550 and the nesting members 530 are easily peeled apart. This allows for a quick transition to the next cutting process, improving processing efficiency. Furthermore, the processing time required can be reduced.

[0075] Furthermore, since the second member 520 is composed of a plurality of nesting members 530, it is possible to selectively arrange the ejector pins 408. Furthermore, it is possible to arrange the nesting members 530 according to the size of the stacked body 550 to be formed, eliminating the need to prepare more nesting members 530 than necessary. Furthermore, since the nesting members 530 are provided with the first through holes 531, it is possible to obtain an anchor effect for each nesting member 530, and even when the stacked body 550 is selectively formed, it is possible to form the stacked body 550 without affecting the forming process.

[0076] Furthermore, in the manufacturing method of the molding die 600 of this embodiment, the insert member 530 preferably has at least one first through hole 531. According to this method, the insert member 530 has the first through hole 531, which allows the molding material 550A to enter into the first through hole 531, thereby improving the anchor effect, i.e., the adhesion between the base plate 500A including the insert member 530 and the laminate 550. Furthermore, for example, an ejector pin 408 for pushing out the product 700 from the laminate 550 can be disposed in the first through hole 531 or another through hole 552.

[0077] Furthermore, in the manufacturing method of the molding die 600 of this embodiment, it is preferable that the plurality of nesting members 530 have the same shape and the same diameter of the first through holes 531. According to this method, since the plurality of nesting members 530 have the same shape and the same diameter of the first through holes 531, it is possible to fill the openings 511 with the nesting members 530 without having to worry about the order in which the nesting members 530 are inserted into the openings 511. Furthermore, since the nesting members 530 are the same, they can be formed without increasing the number of steps.

[0078] Furthermore, in the manufacturing method of the forming die 600 of this embodiment, it is preferable that the inserting member 530 has an internal thread portion 532 formed on the side opposite to the side on which the laminate 550 is formed. According to this method, since the internal thread portion 532 is formed in the inserting member 530, it can be used, for example, when inserting and removing the inserting member 530 into and from the opening 511 of the first member 510.

[0079] Furthermore, in the method for manufacturing forming die 600 of the present embodiment, it is preferable to provide bolt member 533 having male thread portion 534 that corresponds to female thread portion 532. According to this method, since bolt member 533 that corresponds to female thread portion 532 is provided, forming die 600 can be assembled and disassembled by attaching bolt member 533 to female thread portion 532.

[0080] Furthermore, in the manufacturing method of molding die 600 of this embodiment, the step of removing second member 520 preferably involves joining bolt member 533 to internal thread portion 532 and removing insert member 530 together with bolt member 533 from base plate 500A. According to this method, because bolt member 533 is joined to internal thread portion 532 of insert member 530, insert member 530 can be relatively easily pulled out from base plate 500A by pulling bolt member 533. Therefore, compared to a case where bolt member 533 is not used, it is possible to improve manufacturing efficiency and shorten manufacturing time.

[0081] Furthermore, in the manufacturing method of the molding die 600 of this embodiment, it is preferable that the longitudinal direction of the insert member 530, i.e., the direction along the Y direction, is the same as the longitudinal direction of the base plate 500A, i.e., the direction along the Y direction. This method makes it possible to reduce the gap between the base plate 500A and the multiple insert members 530, thereby preventing rattling between the opening 511 and the insert members 530. Furthermore, since the insert members 530 do not become elongated more than necessary, the strength of the insert members 530 can be maintained.

[0082] Furthermore, in the method for manufacturing the molding die 600 of this embodiment, the first member 510 has a second through hole 512, and the diameter of the second through hole 512 is preferably larger than the diameter of the first through hole 531. According to this method, the diameter of the second through hole 512 of the first member 510 is larger than the diameter of the first through hole 531 of the insert member 530, and therefore the adhesion between the laminate 550 and the first member 510, in other words, the adhesion around the insert member 530, can be increased. Therefore, compared to when the adhesion between the insert member 530 and the laminate 550 is high, warping of the laminate 550 can be suppressed.

[0083] In addition, the base plate 500A of this embodiment is a base plate 500A on which the molding material 550A used in the injection molding apparatus 10 is laminated, and has a first member 510 and a second member 520, and the first member 510 has an opening 511, and the second member 520 is preferably composed of a plurality of nesting members 530, which are arranged and positioned so as to fill the opening 511.

[0084] According to this configuration, a stacked body 550 is formed by stacking a modeling material 550A on a base plate 500A on which a plurality of nesting members 530 are arranged so as to fill the opening 511. Therefore, the adhesion between the stacked body 550 and each nesting member 530 is lower than the adhesion between the stacked body 550 and the second member 520 when, for example, the second member 520 is composed of a single member. Therefore, when removing the second member 520 from the base plate 500A, each nesting member 530 can be easily removed. In other words, the nesting members 530 can be easily removed from the base plate 500A. This allows the work to proceed to the next process quickly, improving processing efficiency. Furthermore, the processing time can be reduced.

[0085] Modifications of the above-described embodiment will now be described.

[0086] As described above, the first through hole 531 of the nesting member 530 is not limited to having the same hole diameter from the first surface 530a on which the laminate 550 is formed to the second surface 530b opposite the first surface 530a, and may have a tapered shape.

[0087] Specifically, for example, it is preferable that the first through hole 531 has a tapered shape in which the hole diameter becomes smaller from the first surface 530a of the insert member 530 on which the laminate 550 is formed to the second surface 530b opposite the first surface 530a.

[0088] According to this method, the hole diameter decreases from the first surface 530a to the second surface 530b, in other words, the hole diameter is larger on the side of the laminate 550 and smaller on the side of the support plate 540, making it easier to separate the laminate 550 from the insert member 530. Note that the tapered shape is not limited to the first through hole 531, and may also be applied to the second through hole 512 of the first member 510.

[0089] As described above, the shape of nesting member 530 is not limited to a rectangular parallelepiped, and may be any shape that can be inserted into opening 511 of first member 510. For example, it may be a combination of a nesting member that is concave in plan view with a nesting member that is rectangular, or it may be a combination of nesting members 530 that are divided in half and have a smaller shape. [Explanation of symbols]

[0090] 10...injection molding apparatus, 101...accommodating section, 110...plasticizing device, 111...first flat screw, 112...barrel, 113...first heater, 114...first nozzle, 115...screw driving section, 116...outlet hole, 120...injection control mechanism, 121...injection cylinder, 122...plunger, 123...plunger driving section, 124...check valve, 130...mold clamping device, 131...mold driving section, 132...bo 300...three-dimensional modeling device, 309...second heater, 310...modeling unit, 311...second nozzle, 312...material supply section, 313...plasticization section, 314...discharge section, 315...material supply path, 316...second flat screw, 317...second barrel, 318...discharge amount Adjustment unit, 319... valve drive unit, 320... cutting unit, 321... cutting tool, 330... stage, 340... moving mechanism, 350... control unit, 400... fixed mold, 406... support rod, 407... ejection mechanism, 408... ejector pin, 409... support plate, 411... spring, 412... ejection plate, 413... thrust bearing, 500... movable mold, 500A... base plate, 510... first member, 511, 511a, 511b, 511c 11b...opening, 512...second through hole, 520...second member, 530...nesting member, 530a...first surface, 530b...second surface, 531...first through hole, 532...female thread portion, 533...bolt member, 534...male thread portion, 540...support plate, 550...laminated body, 550A...molding material, 551...cavity, 552...through hole, 560...mold base, 561...opening, 600...molding mold, 700...product.

Claims

1. A method for manufacturing a mold used in an injection molding apparatus, comprising: a step of assembling a base plate by inserting a second member composed of a plurality of nesting members into an opening of the first member; a step of discharging a modeling material onto the base plate to stack layers to form a laminate that will become a part of the mold; removing the second member from the base plate on which the laminate is formed; a step of cutting the laminate; and In the step of assembling the base plate, the plurality of insert members are arranged and inserted so as to fill the openings.

2. A method for manufacturing the molding die according to claim 1, The insert member has at least one first through hole.

3. A method for manufacturing the molding die according to claim 2, comprising the steps of: The method for manufacturing a molding die, wherein the plurality of insert members have the same shape and the first through holes have the same diameter.

4. A method for manufacturing the molding die according to claim 1, The method for manufacturing a molding die, wherein the insert member has a female thread portion formed on a side opposite to a side on which the laminate is formed.

5. A method for manufacturing the molding die according to claim 4, comprising the steps of: A method for manufacturing a molding die including a bolt member having a male thread portion corresponding to the female thread portion.

6. A method for manufacturing the molding die according to claim 5, In the step of removing the second member, the bolt member is joined to the female thread portion, and the insert member is removed from the base plate together with the bolt member.

7. A method for manufacturing the molding die according to claim 1, A method for manufacturing a molding die, wherein the longitudinal direction of the insert member is the same as the longitudinal direction of the base plate.

8. A method for manufacturing the molding die according to claim 2, comprising the steps of: A method for manufacturing a molding die, wherein the first through hole has a tapered shape in which the hole diameter decreases from a first surface of the insert member on which the laminate is formed to a second surface opposite the first surface.

9. A method for manufacturing the molding die according to claim 2, the first member has a second through hole; A method for manufacturing a molding die, wherein the diameter of the second through hole is larger than the diameter of the first through hole.

10. A base plate on which a molding material is deposited for use in an injection molding apparatus, comprising: A first member and a second member are included. The first member has an opening, The second member is a base plate, which is made up of a plurality of nesting members arranged so as to fill the opening.

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