Model parts and manufacturing method of model parts

Abstract

To provide a model component in which a base layer of stable quality can be seen from the outside, and a method for manufacturing the same. [Solution] A model part having a first layer formed of a first material of a first color, and a second layer formed to cover at least a portion of the first layer, the second layer being made of a second material of a second color, wherein the melting point of the first material is higher than the melting point of the second material, and the first layer is visible from the outside through the second layer.

Description

[Technical Field]

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

[0002] When coloring the parts (also called components) of assembled models known as plastic models (registered trademarks), such as the faces of toys, each part is painted by hand or spray-painted using a mask with openings in the areas to be painted (see Patent Document 1). Also, an automated painting system has been proposed that uses a coloring device equipped with multiple printing machines and conveyors (see Patent Document 2). [Prior art documents] [Patent documents]

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

[0004] However, creating a gradation of color that gradually darkens requires skill, and it is difficult to achieve consistent quality. Furthermore, using a painting device requires additional capital investment and increases the size of the equipment. It has also been difficult to produce model parts with a consistent, visible base layer.

[0005] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a model component in which a base layer of stable quality can be visually confirmed from the outside, and a method for manufacturing the same. [Means for solving the problem]

[0006] The invention of model parts a first layer formed of a first material of a first color; a second layer formed to cover at least a portion of the first layer, the second layer being made of a second material and having a second color; and and the melting point of the first material is higher than the melting point of the second material; The first layer is externally visible through the second layer. The invention of model parts also A model part that is combined with other model parts to form a doll toy, a first layer formed of a first material of a first color; a second layer formed to cover at least a portion of the first layer, the second layer being made of a second material and having a second color; and and the melting point of the first material is higher than the melting point of the second material; the first layer is externally visible through the second layer; the first layer is connected to a first runner made of the first material for fixing the model part, and the second layer is connected to a second runner made of the second material for fixing the model part; the first layer constitutes a body part of the doll toy; The second layer constitutes the clothing of the doll toy.

[0007] The invention relates to a method for manufacturing a model part, which includes a first step of molding a first layer using a first material of a first color, and a second step of molding a second layer using a second material of a second color so as to cover at least a portion of the first layer, wherein in the second step, the second layer is molded before the first layer is cooled to room temperature, the melting point of the first material is higher than the melting point of the second material, and the first layer is visible from the outside through the second layer. The invention also provides a method for manufacturing a model component that is combined with other model components to form a doll toy, the method comprising: a first step of molding a first layer using a first material of a first color; and a second step of molding a second layer using a translucent second material of a second color so as to cover at least a part of the first layer, wherein in the second step, molding of the second layer is initiated at a predetermined temperature before the first layer is cooled to room temperature, the melting point of the first material is higher than the melting point of the second material, the first layer is visible from the outside through the second layer, the first layer is connected to a first runner formed of the first material for fixing the model component, and the second layer is connected to a second runner formed of the second material for fixing the model component, the first layer constitutes a body part of the doll toy, and the second layer constitutes a costume of the doll toy. In the second step, the second layer is molded by pouring the second material into a cavity formed between the mold and a second surface opposite to the first surface, with the entire first surface of the first layer being directly supported by the mold, and the second layer is formed on the second surface and not on the first surface of the model component. . [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a model component in which a base layer of stable quality can be seen from the outside, and a method for manufacturing the same. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a flowchart illustrating an example of a method for manufacturing a model component according to an embodiment of the present invention. [Figure 2] 1A to 1C are diagrams illustrating a molded product produced according to a method for manufacturing a model component according to an embodiment of the present invention. [Figure 3] 1A and 1B are diagrams for explaining the structure of a model component corresponding to an embodiment of the present invention. [Figure 4] 1A and 1B are diagrams for explaining a cross-sectional structure of a model part corresponding to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings. Note that the same reference numerals in each drawing indicate the same elements. Furthermore, in each drawing, the up, down, left, and right directions on the paper surface will be used in the description of the present embodiment as the up, down, left, and right directions of the parts (or components) in this embodiment. Note that in the embodiments described below, the present invention will exemplify molding materials such as ABS (acrylonitrile-butadiene-styrene) resin and SBC (styrene-butadiene copolymer, a styrene-based special transparent resin), but this is not intended to be limiting, and the use of other materials (thermoplastic resins such as polyethylene, thermosetting resins, soft resins, metals, etc.) is not excluded.

[0011] First, a method for manufacturing a model part according to an embodiment of the present invention will be described with reference to the flowchart in FIG. 1. In S101, primary molding is performed to form a primary molding layer that constitutes the skeleton of the model part. ABS can be used as the molding material (raw material) for the primary molding layer. Next, in S102, secondary molding is performed to form a secondary molding layer on the surface of the primary molding layer before the primary molding layer cools to room temperature. SBC can be used as the molding material for the secondary molding layer. The secondary molding layer forms the outer surface (skin) of the model part, and is formed so that the degree to which the color of the primary molding layer formed underneath is visible through the secondary molding layer varies depending on the thickness of the secondary molding layer.

[0012] In the above process, the molding material constituting the primary molding layer has an opaque color (e.g., flesh color, white, red, or other color, such as a solid color, metallic color, or pearl color) or a translucent (or even transparent) color (e.g., flesh color, white, red, or other color). The molding material of the secondary molding layer has a transparent or translucent color. For example, if the model component constitutes a doll's torso part, the secondary molding layer constituting the surface may be clear orange (transparent orange), while the primary molding layer may be white or flesh colored. In this case, making the secondary molding layer transparent or translucent makes it possible to express the appearance of wearing transparent or sheer clothing on the skin. The colors of the secondary molding layer and the primary molding layer may be the same or similar colors, or may be similar or opposite colors, as long as the secondary molding layer is formed with a higher transparency. In this embodiment, the primary molding layer and the secondary molding layer are formed using molding materials of different colors, and the secondary molding layer is formed using a clear material or a translucent material, allowing the primary molding layer of a different color underneath to be seen through, making it possible to express gradation.

[0013] The molding materials for each molding layer can be made of a common material to bond and integrate the primary and secondary molding layers. For example, PS, KPS, and GPPS share the same polystyrene material, despite their different properties. However, if the melting points of the materials are similar, forming the secondary molding layer on top of the primary molding layer can result in erosion of the primary molding layer due to the heat of the secondary molding layer and the frictional heat generated during injection molding, resulting in a roughened surface. If the secondary molding layer is opaque, this is not a problem because the roughness of the primary molding layer, which is the underlying layer, cannot be seen from the outside. However, if the secondary molding layer is transparent or translucent, the surface of the primary molding layer can be seen through the secondary molding layer, resulting in a roughened surface. On the other hand, if different materials (materials with different properties) are used for the primary and secondary molding layers, the bonding strength between the layers is weakened, resulting in the secondary molding layer easily peeling from the primary molding layer after molding.

[0014] In this embodiment, the primary molding layer is formed from ABS, and the secondary molding layer is formed from a different material, SBC. The melting point of ABS is 100 to 110°C, while the melting point of SBC is 80 to 100°C. Therefore, even if the primary molding layer is formed from ABS in the primary molding process and then the secondary molding layer is formed from SBC in the secondary molding process, the primary molding layer will not be eroded in the secondary molding process due to the difference in melting points. Therefore, roughness of the primary molding layer will not be visible through the secondary molding layer. Furthermore, in this embodiment, the primary molding layer is formed from ABS, and then the secondary molding layer is formed without cooling to room temperature, thereby maintaining the bonding strength between the layers. The temperature of the primary molding layer at the start of the secondary molding process may be a predetermined temperature higher than room temperature (e.g., 40 to 50°C, 30 to 60°C, or any range within this range) that allows it to be touched by hand.

[0015] The manufacturing method for a model part consisting of the above two-stage molding process can be carried out using, for example, a multi-color molding apparatus. Each molding process uses a mold corresponding to that process. Specifically, molding material is poured into the runner grooves of the mold or the molding spaces (cavities) for molding each part to form a molded product, and then the molded product is removed from the mold. The primary molded product produced in the primary molding process is attached to the mold for the secondary molding process, and the secondary molding is carried out. In this case, after the primary molding, the primary molded product is attached to the mold for the secondary molding process without being cooled to room temperature. The molding method using a multi-color molding apparatus itself is well known, so a detailed description will be omitted.

[0016] In addition, although the above describes the case where the primary molding layer is molded in a single molding process, the primary molding layer may be divided and the primary molding may be performed twice depending on the thickness of the primary molding layer to be molded and the color of the material. In this case, the molding process performed will be three stages. By molding the primary molding layer in two stages, dents and distortions on the molding can be reduced, and a molded product with a uniform appearance can be created.

[0017] Next, referring to Figure 2, the molding procedure from the primary molding layer to the secondary molding layer will be described in accordance with the molding method of Figure 1 corresponding to this embodiment. Figure 2 is a cross-sectional view of the molding die and molded product during the molding process. Figures 2(A) and 2(B) correspond to the primary molding in S101. As shown in Figure 2(A), the molding die (male die 201 and female die 202; the assignment of male and female dies may be reversed) has a cavity 203 corresponding to the primary molding layer to be molded, and ABS molding material is poured into this cavity 203 via main and sub-runners (not shown) to form a part.

[0018] Then, as shown in FIG. 2(B), a molded product 204 is produced in a primary molding using a male mold 201 and a female mold 202. The molded product 204 is composed of a main runner, an auxiliary runner, and a primary molding layer. The molded product 204 is made of ABS. The main runner is formed to surround the periphery of the part, and the part is fixed to the main runner by being connected to the main runner via the auxiliary runner. The main runner and auxiliary runner correspond to grooves for flowing molding material into the cavity 203 in the molding dies 201 and 202. In the primary molding of S101, the molding material is flowed from the main runner groove through the auxiliary runner groove in the molding dies 201 and 202 into the cavity 203, filling the cavity, the main runner groove, and the auxiliary runner groove. After that, the molding material is cooled to a temperature that can be touched by hand (the above-mentioned predetermined temperature), thereby producing the molded product 204 including the primary molding layer.

[0019] Next, in the secondary molding in S102, a secondary molding layer is formed to cover the upper side of the primary molding layer, which is maintained at a predetermined temperature. Figures 2(C) and 2(D) correspond to the secondary molding in S102. As shown in Figure 2(C), a cavity 212 corresponding to the secondary molding layer to be formed in the secondary molding is formed between the mold 211 and the molded product 204. The molding material SBC is then poured into this cavity 212 via a main runner and a sub-runner (not shown). This results in the formation of a molded product 213 including a secondary molding layer, as shown in Figure 2(D), in which the primary molding layer is at least partially covered with SBC. The molded product 213 is composed of the main runner, the sub-runner, and the secondary molding layer. In this embodiment, the secondary molding layer is formed by forming SBC on the upper surface of the ABS primary molding layer from the main runner through the sub-runner. At this time, the underside of the primary molding layer is supported by the molding die 202, so the position of the molding 204 does not fluctuate, and it is possible to accurately form the molding 213 so that the thickness of the secondary molding layer is the desired thickness.

[0020] In the secondary molding of S102, after the molded product 204 is fixed inside the molding dies 211 and 202, the molding material (SBC) is flowed from the main runner groove through the sub-runner groove into the cavity 213, filling the cavity 213, the main runner groove and the sub-runner groove, and then cooling to form the molded product 213 on the upper surface of the molded product 204.

[0021] Next, an example of the structure of a model part manufactured according to the manufacturing method shown in FIGS. 1 and 2 will be described with reference to FIG. 3. FIG. 3(A) is a diagram showing an example of a model part 300 as part of the body of a doll toy, manufactured by a molding process corresponding to this embodiment. The outer surface 302 of the model part 300 is composed of a secondary molding layer, and a part of the primary molding layer 301 covered by the secondary molding layer is exposed to the outside as a connecting part. The connecting part functions as a connecting member for connecting to other parts.

[0022] FIG. 3(B) is a diagram showing the separation of the model part 300 into multiple molding layers. FIG. 3(B) shows a case where the primary molding is performed in two stages. That is, the primary molding layer 301 is composed of the first molding layer 311 and the second molding layer 312, and the secondary molding layer 302 is composed of the third molding layer 313. The first molding layer 311 and the second molding layer 312 have different colors, but together they form the skeleton of the model part. The third molding layer 313 forms the outer skin of the model part. For simplicity, the first molding layer 311 and the second molding layer 312 will be collectively referred to as the "skeleton," and the third molding layer 313 will be collectively referred to as the "outer skin."

[0023] In this embodiment, the outer skin is made of a transparent material and covers the skeleton, with an uneven surface. The outer skin is a molded layer that forms the surface of the model component 200, and has a surface that corresponds to the desired outer shape of the model. Since the model component 200 is part of the body of the doll toy, the surface shape of the outer skin expresses the unevenness of the body.

[0024] When comparing the shapes of the outer surfaces of the skeleton and the skin, they are configured to include both similar and dissimilar portions. The thickness of the skin is maintained at a predetermined value for the similar portions. On the other hand, the dissimilar portions are formed to have a thickness different from that of the similar portions, and the color of the skeleton, which can be visually recognized from the outside through the skin, changes in accordance with the change in thickness. For example, if the skin is made of a translucent (e.g., clear orange) material and the skeleton is made of a white or flesh-colored material, the white or flesh color of the skeleton will be visible through the clear orange skin, or conversely, the orange will be more pronounced.

[0025] In this case, the thickness of the skin is kept constant in areas with similar external shapes, so the color of the skeleton visible through the translucent skin remains constant. However, as the skin becomes thicker, the orange color becomes stronger. Also, as the skin becomes thinner, the skin color and white color become stronger. By adjusting the thickness of the skin in this way, it is possible to strengthen the skin color or, conversely, strengthen the orange color. For example, the unevenness of the torso can be expressed by thinning the skin thickness at the convex parts of the skeleton to strengthen the skin color, and thickening the skin thickness at the concave parts to strengthen the orange color.

[0026] Next, the cross-sectional structure of the model component 300 according to this embodiment will be described. FIG. 4A is a diagram showing an example of how the thickness of the outer skin portion of the model component 300 shown in FIG. 3A varies. As shown in the cross-sectional view of FIG. 4A, the outer skin portion constituting the outer surface of the model component 300 has thicknesses D1, D2, and D3, with thickness increasing in the order D1 > D2 > D3. In the component D1, the orange color of the outer skin portion appears darker. However, as the outer skin portion becomes thinner, as in D2 and D3, the orange color weakens and the flesh color of the skeleton portion becomes stronger instead. The thicker the portion, the greater the degree to which the color of the outer skin portion blends with the color of the skeleton portion, resulting in a greater change in color when the model component 300 is viewed from the outside.

[0027] By varying the thickness of the skin part partially or entirely in this way, it is possible to vary the color tone when viewed from the outside of the model component 300. In this case, in the parts where the skin part becomes continuously thicker, the degree to which the color of the skin part is mixed with the color of the skeleton part gradually increases, so that from the darkest part where the color of the skeleton part is visible through, the color gradually becomes lighter and changes to the color of the skin part itself, allowing the viewer to observe a gradation on the surface of the model component 300.

[0028] The appearance of the gradation can be changed by changing the thickness of the outer skin. For example, the way the color changes from dark to light varies depending on whether the change in thickness is steep or gradual, allowing for different gradation expressions. The thickness may also be changed in the direction of decreasing, which allows for a change from light to dark colors.

[0029] While Fig. 4(A) illustrates an example in which a gradation effect is achieved by varying the thickness of the outer skin, the present invention is not limited to the above embodiment. For example, the thickness of the outer skin may be constant. Fig. 4(B) illustrates an example of the model component 300 in Fig. 3(A) in which the outer skin has a uniform thickness. As shown in the cross-sectional view of Fig. 4(B), the thickness of the outer skin that constitutes the outer surface of the model component 300 is uniform.

[0030] In the above, the case where the primary molding layer is formed from ABS and the secondary molding layer is formed from SBC has been described, but the combination of materials is not limited to this. For example, the primary molding layer may be formed from ABS and the secondary molding layer from TPE (Thermoplastic elastomer: thermoplastic elastomer, particularly styrene-based thermoplastic elastomer). The primary molding layer may also be formed from KPS (reinforced polystyrene) and the secondary molding layer from TPE. Alternatively, the primary molding layer may be formed from a first material with a higher melting point and the secondary molding layer from a second material with a lower melting point.

[0031] As described above, according to this embodiment, it is possible to provide a model component in which the base layer of stable quality can be seen from the outside, and a method for manufacturing the same.

Claims

1. A method of manufacturing a model part that is combined with other model parts to form a doll toy, a first step of forming a first layer using a first material of a first color; a second step of molding a second layer using a second material of a translucent second color so as to cover at least a portion of the first layer; Including, In the second step, molding of the second layer is started at a predetermined temperature before the first layer is cooled to room temperature; the melting point of the first material is higher than the melting point of the second material; the first layer is visible from the outside through the second layer; the first layer is connected to a first runner made of the first material for fixing the model part, and the second layer is connected to a second runner made of the second material for fixing the model part; the first layer constitutes a body part of the doll toy; the second layer constitutes a costume for the doll toy; In the second step, the second layer is molded by pouring the second material into a cavity formed between the mold and a second surface opposite to the first surface, with the entire first surface of the first layer being directly supported by the mold; In the model part, the second layer is formed on the second surface and not on the first surface. Manufacturing method for model parts.

2. the first material is an acrylonitrile butadiene styrene (ABS) resin and the second material is a styrene butadiene copolymer (SBC) resin; or the first material is an acrylonitrile butadiene styrene (ABS) resin and the second material is a thermoplastic elastomer (TPE) resin; or 2. The method of claim 1, wherein the first material is a reinforced polystyrene (KPS) resin and the second material is a thermoplastic elastomer (TPE) resin.

3. 3. The method for manufacturing a model part according to claim 1, wherein the predetermined temperature is in the range of 30 to 60 degrees.

4. 3. The method for manufacturing a model component according to claim 1, wherein the predetermined temperature is in the range of 40 to 50 degrees.

5. 5. The method for manufacturing a model part according to claim 1, wherein the second layer includes portions with different thicknesses.

6. 6. A method for manufacturing a model part according to claim 1, wherein the transparency of the first color is lower than the transparency of the second color.

7. A method for producing a model part according to any one of claims 1 to 6, wherein the first colour is opaque.

8. A method for producing a model part according to any one of claims 1 to 6, wherein the first colour is translucent.

9. The first step includes a step of further molding the first layer with the first material of a third color different from the first color and the second color; 9. A method for producing a model part according to any one of claims 1 to 8, wherein the first layer includes a portion formed of the first material of the third color.

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