Formwork and molding method

Abstract

When molding resin, there is a risk that the resin may not be able to be molded into a predetermined shape due to the relative movement of multiple structures and / or the penetration of resin into their interfaces. In view of this, a mold is provided that facilitates the molding of resin into a predetermined shape. [Solution] A mold for molding resin into a predetermined shape, wherein a first structure and a second structure, which are separable from each other, are brought into close contact using magnetic force, thereby defining a recess corresponding to the predetermined shape.

Description

Technical Field

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[0001] The present invention relates to a mold for molding a resin into a predetermined shape and a molding method for molding the resin into a predetermined shape.

Background Art

[0002] The molding of a resin into a predetermined shape is generally performed using a mold (see, for example, Patent Document 1). The mold may be configured by combining a plurality of separable structures. In this case, a concave portion having a shape corresponding to the predetermined shape is defined by combining the plurality of structures.

[0003] For example, a concave portion is defined by disposing a seal material in the shape of a square tube serving as a side wall on a flat plate serving as a bottom wall. And in this case, for example, the resin is molded into a predetermined shape by filling the concave portion with the resin and then heating and curing it.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] When molding a resin as described above, there is a risk that the resin cannot be molded into a predetermined shape due to the relative movement of a plurality of structures and / or the intrusion of the resin into the interface between them. In view of this point, an object of the present invention is to provide a mold and a molding method that facilitate molding of a resin into a predetermined shape.

Means for Solving the Problems

[0006] According to one aspect of the present invention, a mold is provided for molding a resin into a predetermined shape, wherein a recess corresponding to the predetermined shape is defined by using magnetic force to bring together a first structure and a second structure that are separable from each other.

[0007] Preferably, the first structure has a bottom wall member that forms the bottom wall of the recess, and the second structure has a first side wall member and a second side wall member that are separable from each other and arranged on the bottom wall member so as to connect the two, thereby forming the side walls of the recess. Furthermore, it is preferable that the first side wall member includes a linearly extending first portion and a second portion that extends from one end of the first portion so as to be perpendicular to the first portion, and the second side wall member includes a linearly extending third portion that is equal in length to the first portion and a fourth portion that extends from one end of the third portion so as to be perpendicular to the third portion and is equal in length to the second portion, and that the first side wall member and the second side wall member can be arranged on the bottom wall member so as to connect the first portion and the fourth portion and the second portion and the third portion in each of a plurality of states in which the distance between the first portion and the third portion is equal but the distance between the second portion and the fourth portion is different.

[0008] According to another aspect of the present invention, a molding method for molding a resin into a predetermined shape is provided, comprising: defining a recess corresponding to the predetermined shape by using magnetic force to bring a first structure and a second structure into close contact; filling the recess with the resin; molding the resin into the predetermined shape by heating and curing the resin filling the recess; and separating the first structure and the second structure to dismantle the recess used for molding the resin into the predetermined shape.

[0009] It is preferable that the resin is molded into the predetermined shape by heating it to a temperature that does not exceed the heat resistance temperature of the permanent magnet contained in at least one of the first structure or the second structure. Furthermore, it is preferable that the first structure has a bottom wall member that forms the bottom wall of the recess, and the second structure has a first side wall member and a second side wall member that are separable from each other and arranged on the bottom wall member so as to connect the two, thereby forming the side walls of the recess, and that the resin molded into the predetermined shape is removed from the bottom wall member after separating the first side wall member and the second side wall member. [Effects of the Invention]

[0010] In this invention, a first structure and a second structure, which are separable from each other, are brought into close contact using magnetic force. This allows the first and second structures to move relative to each other and / or makes it difficult for resin to penetrate to their interface. As a result, it becomes easier to mold the resin into a predetermined shape. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1(A) is a schematic perspective view showing an example of the first structure, and Figure 1(B) is a cross-sectional view showing the first structure shown in Figure 1(A) along the line 1B-1B. [Figure 2] Figure 2(A) is a schematic perspective view showing an example of the second structure, and Figure 2(B) is a cross-sectional view showing the second structure shown in Figure 2(A) along the line 2B-2B. [Figure 3] Figure 3 is a schematic flowchart illustrating an example of a molding method for molding resin into a predetermined shape using the first structure shown in Figures 1(A) and 1(B) and the second structure shown in Figures 2(A) and 2(B). [Figure 4] Figure 4(A) is a schematic perspective view showing an example of the delimitation step shown in Figure 3, and Figure 4(B) is a schematic perspective view showing another example of the delimitation step shown in Figure 3. [Figure 5]Figure 5 is a schematic cross-sectional view showing an example of the filling step shown in Figure 3. [Figure 6] Figure 6 is a schematic cross-sectional view showing an example of the molding steps shown in Figure 3. [Figure 7] Figure 7 is a schematic cross-sectional view showing an example of the disassembly steps shown in Figure 3. [Figure 8] Figure 8(A) is a schematic perspective view showing another example of the first structure, and Figure 8(B) is a cross-sectional view showing the first structure shown in Figure 8(A) along the line 8B-8B. [Figure 9] Figure 9(A) is a schematic perspective view showing another example of the second structure, and Figure 9(B) is an exploded perspective view of the second structure shown in Figure 9(A). [Modes for carrying out the invention]

[0012] Embodiments of the present invention will be described with reference to the attached drawings. Figures 1(A), 1(B), 2(A), and 2(B) schematically show a first structure and a second structure that can be combined with each other to form a mold for molding resin into a predetermined shape.

[0013] Specifically, Figure 1(A) is a schematic perspective view showing an example of the first structure (structure 10), and Figure 1(B) is a cross-sectional view showing the cross-section of structure 10 along the line 1B-1B. Furthermore, Figure 2(A) is a schematic perspective view showing an example of the second structure (structure 20), and Figure 2(B) is a cross-sectional view showing the cross-section of structure 20 along the line 2B-2B.

[0014] The structure 10 has a bottom wall member 12 which forms the bottom wall of a recess corresponding to the predetermined shape. This bottom wall member 12 is fixed to each other and includes a flat upper layer 12a and a lower layer 12b.

[0015] Note that there is no limitation on the material of the upper layer 12a. However, from the perspective of facilitating the separation from the bottom wall member 12 of the molded resin, it is preferable that the upper layer 12a is made of a plastic such as polypropylene (PP) or polyethylene (PE).

[0016] Also, the lower layer 12b is made of a magnetic material. Examples of this magnetic material include soft magnetic materials such as electromagnetic pure iron or ferrite-based stainless steel, or hard magnetic materials such as neodymium magnets or ferrite magnets.

[0017] The structure 20 has a first side wall member 22 and a second side wall member 24 that are separable from each other and are arranged on the bottom wall member 12 so as to connect the two, serving as the side walls of the concave portion. Each of the first side wall member 22 and the second side wall member 24 extends in an L shape.

[0018] Specifically, the first side wall member 22 includes a first portion 22a that extends linearly and a second portion 22b that extends from one end of the first portion 22a so as to be orthogonal to the first portion 22a. The second side wall member 24 includes a third portion 24a that extends linearly and has the same length as the first portion 22a, and a fourth portion 24b that extends from one end of the third portion 24a so as to be orthogonal to the third portion 24a and has the same length as the second portion 22b.

[0019] In FIG. 2(A), for the sake of convenience, a structure 20 is shown in which the lengths of the first portion 22a and the third portion 24a are equal to the lengths of the second portion 22b and the fourth portion 24b, respectively, but the two lengths may be different.

[0020] Also, a magnetic part 26 is incorporated in the first side wall member 22. The magnetic part 26 is exposed so that its lower surface is flush with the lower surface of the first side wall member 22. The magnetic part 26 includes, for example, an L-shaped lower surface that is exposed on both the lower surface of the first portion 22a and the lower surface of the second portion 22b.

[0021] Alternatively, the magnetic portion 26 may include a linear, circular, or polygonal lower surface that is exposed only on the lower surface of the first portion 22a. In this case, the second portion 22b may contain a similar magnetic portion separate from the magnetic portion 26. Furthermore, in this case, multiple magnetic portions similar to the magnetic portion 26 may be contained in each of the first portion 22a and the second portion 22b.

[0022] Similarly, the second side wall member 24 incorporates a magnetic portion 28. This magnetic portion 28 is exposed such that its lower surface is flush with the lower surface of the second side wall member 24. The magnetic portion 28 includes, for example, an L-shaped lower surface that is exposed on both the lower surface of the third portion 24a and the lower surface of the fourth portion 24b.

[0023] Alternatively, the magnetic portion 28 may include a linear, circular, or polygonal lower surface that is exposed only on the lower surface of the fourth portion 24b. In this case, the fourth portion 24b may contain a similar magnetic portion in addition to the magnetic portion 28. Furthermore, in this case, each of the third portion 24a and the fourth portion 24b may contain multiple similar magnetic portions.

[0024] Each magnetic part 26, 28 is configured to adhere tightly to the structure 10 (specifically, the upper layer 12a side of the bottom wall member 12) using magnetic force. For example, if the lower layer 12b of the bottom wall member 12 is made of a soft magnetic material, each magnetic part 26, 28 is a structure made of a hard magnetic material.

[0025] Furthermore, if the lower layer 12b of the bottom wall member 12 is made of a hard magnetic material, then each magnetic part 26, 28 is a structure made of a soft magnetic material or a hard magnetic material. Alternatively, each magnetic part 26, 28 may include an electromagnet and a housing that houses the electromagnet and has its lower surface exposed.

[0026] Furthermore, the first side wall member 22 and the second side wall member 24 may each have a built-in magnetic section for bringing them into close contact at any point. In this case, it becomes possible to selectively configure the side walls of any of a plurality of recesses with different shapes using the first side wall member 22 and the second side wall member 24.

[0027] For example, magnetic components may be built into the first sidewall member 22 and the second sidewall member 24 to bring the end face of the second portion 22b (the side of the second portion 22b furthest from the first portion 22a) into contact with any point on the inner surface of the third portion 24a (the side of the third portion 24a on which the fourth portion 24b is provided). In this case, a structure made of, for example, a hard magnetic material may be built into the vicinity of the end face of the second portion 22b, and one or more structures made of, for example, a soft magnetic material may be built into the third portion 24a so as to extend throughout its entire surface.

[0028] Similarly, magnetic components may be incorporated into the first sidewall member 22 and the second sidewall member 24 to bring the end face of the fourth portion 24b (the face of the fourth portion 24b furthest from the third portion 24a) into contact with any point on the inner surface of the first portion 22a (the side of the first portion 22a on which the second portion 22b is provided). In this case, a structure made of, for example, a hard magnetic material may be incorporated near the end face of the fourth portion 24b, and one or more structures made of, for example, a soft magnetic material may be incorporated throughout the first portion 22a.

[0029] Furthermore, when these magnetic parts are incorporated into the first sidewall member 22 and the second sidewall member 24, it becomes easier to connect the first portion 22a and the fourth portion 24b, and also to connect the second portion 22b and the third portion 24a, so that there is one of several states in which the distance between the first portion 22a and the third portion 24a is equal, but the distance between the second portion 22b and the fourth portion 24b is different.

[0030] In addition, at least one of the first side wall member 22 or the second side wall member 24 may be provided with a scale to facilitate understanding the shape of the side wall of the recess formed by combining the two. For example, a scale indicating the distance from the second portion 22b may be provided on the inner surface, top surface, or outer surface of the first portion 22a, and / or a scale indicating the distance from the fourth portion 24b may be provided on the inner surface, top surface, or outer surface of the third portion 24a.

[0031] Figure 3 is a schematic flowchart illustrating an example of a molding method for molding resin into a predetermined shape using structures 10 and 20. In this method, first, a recess corresponding to the predetermined shape is defined (definition step S1). Figure 4(A) is a schematic perspective view illustrating an example of definition step S1, and Figure 4(B) is a schematic perspective view illustrating another example of definition step S1.

[0032] In this defining step S1, the first side wall member 22 and the second side wall member 24 are connected and placed on the bottom wall member 12 so that recesses 30a and 30b corresponding to the predetermined shape are defined. As a result, magnetic force acts between the bottom wall member 12 and the first side wall member 22 and the second side wall member 24, causing them to be in close contact. Note that the connection configuration of the first side wall member 22 and the second side wall member 24 may change depending on the predetermined shape.

[0033] For example, if the predetermined shape is a square in plan view, where each side is approximately equal in length to the first portion 22a, the recess 30a is defined by connecting the first side wall member 22 and the second side wall member 24 such that the end face of the fourth portion 24b contacts the other end of the first portion 22a, and the end face of the second portion 22b contacts the other end of the third portion 24a (see Figure 4(A)).

[0034] Furthermore, if the predetermined shape is a rectangle in plan view in which each long side is approximately equal in length to the second portion 22b, the recess 30b is defined by connecting the first side wall member 22 and the second side wall member 24 such that the end face of the fourth portion 24b contacts one end and the other end of the first portion 22a, and the end face of the second portion 22b contacts one end and the other end of the third portion 24a (see Figure 4(B)).

[0035] After the definition step S1, resin is filled into the recesses (filling step S2). Figure 5 is a schematic cross-sectional view showing an example of the filling step S2. In this filling step S2, first, the recesses 30a and 30b are positioned directly below the nozzle 2. Then, the resin 1 in a fluid state is supplied to the recesses 30a and 30b from the nozzle 2. This resin 1 is, for example, urethane or epoxy resin.

[0036] After the filling step S2, the resin 1 is molded (molding step S3). Figure 6 is a schematic cross-sectional view showing an example of the molding step S3. In this molding step S3, first, the bottom wall member 12 is placed on the table 4 so that the recesses 30a and 30b are positioned between the lower heater 4a built into the table 4 and the upper heater 6a built into the heating unit 6 located above the table 4. Then, the lower heater 4a and the upper heater 6a are operated to heat and harden the resin 1.

[0037] Here, if at least one of the lower layer 12b of the bottom wall member 12, the magnetic part 26 embedded in the first side wall member 22, or the magnetic part 28 embedded in the second side wall member 24 includes a permanent magnet, it is preferable that the temperature of the heated resin 1 does not exceed the heat resistance temperature of the permanent magnet. The heat resistance temperature of the permanent magnet refers to the lower of the upper limit temperature at which the magnetic force becomes 80% or more compared to the initial magnetic force at room temperature, or the upper limit temperature at which the magnetic force after deheating and returning to room temperature becomes substantially equal to the initial magnetic force.

[0038] The heating of the resin 1 in molding step S3 may be carried out in any manner. For example, the resin 1 may be heated using only the lower heater 4a or the upper heater 6a. If only the lower heater 4a is used, the heating unit 6 does not need to be provided above the table 4. If only the upper heater 6a is used, the table 4 may be replaced with a table that does not incorporate the lower heater 4a. Alternatively, the resin 1 may be heated using a known thermosetting furnace.

[0039] After the molding step S3, the recess is disassembled (disassembly step S4). Figure 7 is a schematic cross-sectional view showing an example of the disassembly step S4. In this disassembly step S4, the first side wall member 22 and the second side wall member 24 are separated and moved away from the bottom wall member 12. This makes it easier to remove the resin 1 molded into a predetermined shape from the bottom wall member 12, which is done thereafter.

[0040] In the embodiment described above, the separable structures 10 and 20 are brought into close contact using magnetic force. This allows structures 10 and 20 to move relative to each other and / or makes it difficult for resin 1 to penetrate their interfaces. As a result, molding of resin 1 into a predetermined shape becomes easier.

[0041] The embodiments described above are merely one aspect of the present invention, and the present invention is not limited to the embodiments described above. For example, the first structure of the present invention may have a bottom wall member partially provided with a magnetic material instead of the bottom wall member 12. Figure 8(A) is a schematic perspective view showing an example of such a first structure (structure 40), and Figure 8(B) is a cross-sectional view showing a cross-section of structure 40 along the line 8B-8B.

[0042] The structure 40 has a flat bottom wall member 42. A magnetic part 44 is embedded in the bottom wall member 42. The magnetic part 44 is exposed so that its lower surface is flush with the lower surface of the bottom wall member 42. The magnetic part 44 is provided in the area of ​​the bottom wall member 42 on which a second structure (for example, structure 20) is expected to be placed.

[0043] Furthermore, the second structure of the present invention may have a first side wall member and a second side wall member that can constitute only the side wall of a recess of a specific shape, instead of the first side wall member 22 and the second side wall member 24. Figure 9(A) is a schematic perspective view showing an example of such a second structure (structure 50), and Figure 9(B) is an exploded perspective view of structure 50.

[0044] Structure 50 has a first side wall member 52 and a second side wall member 54 that are separable from each other and are arranged on the first structure (e.g., structures 20, 40) to connect them, thereby forming the side walls of the recess. Each of the first side wall member 52 and the second side wall member 54 extends in a U-shape (with right angles at its corners).

[0045] Specifically, the first side wall member 52 includes a linearly extending first portion 52a and a second portion 52b extending from each end of the first portion 52a so as to be perpendicular to the first portion 52a. The second side wall member 54 includes a linearly extending third portion 54a that is equal in length to the first portion 52a and a fourth portion 54b extending from each end of the third portion 54a so as to be perpendicular to the third portion 54a.

[0046] In Figure 2(A), for convenience, a structure 50 is shown in which the lengths of the pair of second parts 52b and the pair of fourth parts 54b are equal; however, the lengths may be different. Furthermore, each of the first side wall member 52 and the second side wall member 54 has a magnetic part (not shown) similar to the magnetic parts 26 and 28 described above.

[0047] Furthermore, each of the first side wall member 52 and the second side wall member 54 is provided with a magnetic portion 56 for bringing the end faces of a pair of second portions 52b (the faces of the second portion 52b furthest from the first portion 52a) and the end faces of a pair of fourth portions 54b (the faces of the fourth portion 54b furthest from the third portion 54a) into close contact. This makes it easier to connect the first side wall member 52 and the second side wall member 54.

[0048] Furthermore, the second structure of the present invention may have a first side wall member and a second side wall member that are not provided with magnetic parts for bringing them into close contact with each other. In other words, the second structure of the present invention may have a first side wall member and a second side wall member that are connected by simply bringing them into contact with each other.

[0049] Furthermore, the structures and methods of the embodiments described above can be modified as appropriate without departing from the scope of the present invention. [Explanation of Symbols]

[0050] 1: Resin 2: Nozzle 4: Table (4a: Lower heater) 6: Heating unit (6a: Upper heater) 10: Structure 12: Bottom wall members (12a: upper layer, 12b: lower layer) 20: Structure 22: First side wall member (22a: first part, 22b: second part) 24: Second side wall member (24a: third part, 24b: fourth part) 26:Magnetic part 28:Magnetic part 30a, 30b: Recess 40: Structure 42: Bottom wall member 44:Magnetic part 50: Structure 52: First side wall member (52a: first part, 52b: second part) 54: Second side wall member (54a: third part, 54b: fourth part) 56: Magnetic section

Claims

1. A mold for molding resin into a predetermined shape, A formwork in which a recess corresponding to a predetermined shape is defined by using magnetic force to bring together a first structure and a second structure that are separable from each other.

2. The first structure has a bottom wall member that forms the bottom wall of the recess, The formwork according to claim 1, wherein the second structure has a first side wall member and a second side wall member that are separable from each other and arranged on the bottom wall member so as to connect the two, thereby forming the side wall of the recess.

3. The first side wall member is, The first part extends in a straight line, A second portion extending from one end of the first portion so as to be perpendicular to the first portion, The second side wall member is, A third part that extends in a straight line and is equal in length to the first part, It includes a fourth portion that extends from one end of the third portion so as to be perpendicular to the third portion and is equal in length to the second portion, The formwork according to claim 2, wherein the first side wall member and the second side wall member can be positioned on the bottom wall member to connect the first part and the fourth part, and to connect the second part and the third part, in each of a plurality of states in which the distance between the first part and the third part is equal, but the distance between the second part and the fourth part is different.

4. A molding method for shaping resin into a predetermined form, By using magnetic force to bring the first structure and the second structure into close contact, a recess corresponding to the predetermined shape is defined, Filling the recess with the resin, The resin used to fill the recess is heated and hardened to form the resin into the predetermined shape, By separating the first structure and the second structure, the recess used in molding the resin into the predetermined shape is disassembled, A molding method comprising the following.

5. The molding method according to claim 4, wherein the molding of the resin into the predetermined shape is performed by heating the resin to a temperature that does not exceed the heat resistance temperature of the permanent magnet contained in at least one of the first structure or the second structure.

6. The first structure has a bottom wall member that forms the bottom wall of the recess, The second structure has a first side wall member and a second side wall member that are separable from each other and arranged on the bottom wall member so as to connect the two, thereby forming the side wall of the recess. The molding method according to claim 4 or 5, wherein the resin molded into the predetermined shape is removed from the bottom wall member after separating the first side wall member and the second side wall member.

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