Dip-coated component and method for forming dip-coated product

Abstract

Dip-coated components (P1-P3) comprise: a body part (100) that serves as a product (S); liquid reservoir suction parts (101-103) that are detachably connected to the body part (100); and a dip coating layer (L) that is formed from the body part (100) to the liquid reservoir suction parts (101-103). Adjacent parts (101a-103a) of the liquid reservoir suction parts (101-103) adjacent to the body part (100) extend in series along an edge (100a) of the body part (100). The adjacent parts (101a-103a) are connected to the edges (101a-103a) of the body part (100) over the entire length thereof.

Description

Dip-coated parts and methods for forming dip-coated products

[0001] The present invention relates to dip-coated parts and methods of forming dip-coated products.

[0002] Patent Document 1 discloses a method for forming a coating by dip coating, in which puddles of coating liquid formed on a substrate to be coated are removed, and a coating having a uniform thickness is formed with a high yield without deteriorating the surface smoothness of the coating. In this method, excess coating liquid (liquid puddles, etc.) is attracted by a coating liquid attracting member fixedly installed in a coating liquid tank that stores the coating liquid.

[0003] JP 2016-30225 A

[0004] However, the method of Patent Document 1 requires the preparation of a separate coating liquid attracting member for each component with a different shape. Furthermore, as the shape of the component becomes more complex, a mechanism and control for positioning the coating liquid attracting member with high precision relative to the component becomes necessary, which complicates the dipping device.

[0005] An object of the present invention is to reduce the variation in coating layer thickness of dip-coated products without increasing the complexity of the dipping equipment.

[0006] In one embodiment of the present invention, a dip-coated product forming method includes forming a component having a main body portion to be the product and a liquid reservoir suction portion detachably connected to the main body portion. The adjacent portion of the liquid reservoir suction portion to the main body portion extends continuously along the edge of the main body portion, and the adjacent portion is connected to the edge of the main body portion along its entire length. The component is immersed in coating liquid, and then lifted out of the coating liquid with the adjacent portion positioned below the main body portion, and the layer of coating liquid formed on the component is dried. The liquid reservoir suction portion is separated from the main body portion to form the dip-coated product.

[0007] According to the above method, it is possible to reduce variations in the thickness of the coating layer without increasing the complexity of the dipping device.

[0008] FIG. 1 is a perspective view showing a coating target of Example 1 of the first embodiment. FIG. 2 is a perspective view showing a coating target of Example 2 of the first embodiment. FIG. 3 is a perspective view showing a coating target of Example 3 of the first embodiment. FIG. 4 is a side view showing a liquid pool during vertical lifting in Examples 1 to 3 and the Comparative Example. FIG. 5 is a side view showing a liquid pool during inclined lifting in Examples 1 to 3 and the Comparative Example. FIG. 6 is a side view of a main part of a coating target of a modified example of the first embodiment. FIG. 7 is a perspective view showing a coating target of a second embodiment. FIG. 8 is an enlarged side view showing a portion adjacent to the liquid pool suction portion and the edge of the main body portion of the coating target. FIG. 9 is a view corresponding to FIG. 8 of a modified example of the second embodiment. FIG. 10 is a perspective view showing a coating target of a third embodiment. FIG. 11 is a perspective view showing a coating target of a modified example of the third embodiment. FIG. 12 is a flowchart of a method for forming a dip-coated product according to an embodiment.

[0009] DETAILED DESCRIPTION OF THE INVENTION Dip-coated parts and methods of forming dip-coated products according to several embodiments will now be described with reference to the drawings.

[0010] In the following embodiments, an article to be dip coated (hereinafter, "coating object") is modeled using a 3D printer. The modeling method using a 3D printer can be selected appropriately depending on the constituent material, shape, etc. of the coating object. The material used is not particularly limited as long as it is a material suitable for the coating object, such as metal, resin, or fiber-reinforced resin, and can be used with a 3D printer. An example of the resin is ABS-like 3D Printing Resin manufactured by Phrozen Technology.

[0011] Because the object to be coated is formed by layering materials using a 3D printer, minute irregularities (also known as layering marks) are formed on the surface. By applying a coating liquid to the surface of the object to be coated and filling in the depressions caused by the layering marks, the surface can be smoothed, improving shape accuracy and appearance quality.

[0012] There are no particular limitations on the use, shape, etc. of the product formed from the object to be coated. Examples of the product include interior parts for vehicles, aircraft, etc., housings for electrical appliances, and surface materials for furniture.

[0013] First Embodiment The first embodiment will be described with reference to FIGS. 1 to 5. FIG. 1 shows a coating target 11 according to Example 1 of the first embodiment, FIG. 2 shows a coating target 12 according to Example 2 of the first embodiment, and FIG. 3 shows a coating target 13 according to Example 3 of the first embodiment. Each of the coating targets 11 to 13 includes a main body 100 that will ultimately become the product S (see FIG. 4) and liquid reservoir suction units 101 to 103 that are detachably connected to the main body 100. The main bodies 100 of the coating targets 11 to 13 have the same shape. The liquid reservoir suction units 101 to 103 are detached from the main body 100 before the main body 100 becomes the product S.

[0014] In Example 1, as shown in Figure 1, the main body 100 of the object to be coated 11 and the liquid reservoir suction part 101 are integrally connected. The adjacent part 101a of the liquid reservoir suction part 101 to the main body 100 extends continuously along the edge 100a of the main body 100. The adjacent part 101a is connected to the edge 100a of the main body 100 over its entire length.

[0015] 2, in Example 2, the main body 100 of the coating target 12 and the liquid reservoir suction portion 102 are integrally connected. The adjacent portion 102a of the liquid reservoir suction portion 102, which is adjacent to the main body 100, extends continuously along the edge 100a of the main body 100. The adjacent portion 102a is connected to the edge 100a of the main body 100 over its entire length.

[0016] In Example 3, as shown in Figure 3, the main body 100 of the coating target 13 and the liquid reservoir suction part 103 are integrally connected. The adjacent part 103a of the liquid reservoir suction part 103, which is adjacent to the main body 100, extends continuously along the edge 100a of the main body 100. The adjacent part 103a is connected to the edge 100a of the main body 100 over its entire length.

[0017] As shown in FIG. 1 , in the coating target 11, the surface 100A, which is the design surface of the main body 100, and the surface 101A of the liquid reservoir suction portion 101 are flush and continuous. The main body 100 and the liquid reservoir suction portion 101 are each flat and have a substantially uniform thickness. The liquid reservoir suction portion 101 is thinner than the main body 100. By forming the liquid reservoir suction portion 101 thin, the amount of resin material used can be reduced when the liquid reservoir suction portion 101 is separated from the main body 100 and discarded. A notch 101b is formed in the adjacent portion 101a of the liquid reservoir suction portion 101 along the edge 100a of the main body 100, and the thickness of the adjacent portion 101a gradually decreases toward the edge 100a of the main body 100.

[0018] 2, in the coating target 12, a step is formed between the surface 100A, which is the design surface of the main body 100, and the surface 102A of the liquid pool suction portion 102. With regard to other configurations, the description of the first embodiment can be applied to the description of the second embodiment by replacing the liquid pool suction portion 101 with the liquid pool suction portion 102, the adjacent portion 101a with the adjacent portion 102a, and the notch 101b with the notch 102b.

[0019] 3, the object 13 to be coated has a liquid reservoir suction portion 103, which has a curved portion 103c that curves toward the back surface near its open edge. The intersection angle between the tangent plane at the edge of the curved portion 103c and the extension plane of the surface 100A of the main body 100 is not particularly limited, but in Example 3, it is 26.5°. Regarding other configurations, the description of Example 1 can be applied to the description of Example 3 by replacing adjacent portion 101a with adjacent portion 103a, notch 101b with notch 103b, and surface 101A with surface 103A, respectively.

[0020] A method for forming the dip coated product S will now be described with reference to the flow chart of FIG.

[0021] First, the coating objects 11 to 13 are formed (step S1). The coating objects 11 to 13 are formed as resin parts shaped by 3D printing.

[0022] Next, the objects 11 to 13 to be coated are immersed in the coating liquid stored in the coating liquid tank (step S2). At this time, the main body 100 and the liquid reservoir suction portions 101 to 103, together with the edge 100a and the adjacent portions 101a to 103a, are immersed in the coating liquid.

[0023] Next, the objects to be coated 11-13 are lifted up from the coating liquid with the adjacent portions 101a-103a positioned below the main body 100 (step S3). At this time, the liquid reservoir suction portions 101-103 may be positioned below the main body 100. As a result, a layer of coating liquid is formed on the surface of the objects to be coated 11-13, and excess coating liquid is sucked from the edge 100a of the main body 100 by the liquid reservoir suction portions 101-103. Suction is mainly performed by applying gravity to the layer of coating liquid formed continuously from the surface 100A of the main body 100 to the surfaces 101A-103A of the liquid reservoir suction portions 101-103, causing the coating liquid in the layer to flow down from the main body 100 side to the liquid reservoir suction portions 101-103 side.

[0024] The immersion in and the withdrawal from the coating liquid may be performed by raising and lowering the objects 11 to 13 relative to the stationary coating liquid, or by fixing the objects 11 to 13 in a coating liquid tank and raising and lowering the liquid level of the coating liquid in the coating liquid tank.

[0025] Next, the pulled-up coating targets 11 to 13 are dried (step S4). This forms dip-coated parts P1 to P3. The coating liquid is not particularly limited, and may be, for example, a solvent evaporation type or an ultraviolet curing type. If it is a solvent evaporation type, the layer of the coating liquid can be cured by natural drying or heat drying alone. If it is an ultraviolet curing type, the layer of the coating liquid can be cured by irradiating it with ultraviolet light in addition to drying. An example of an ultraviolet curing type coating liquid is an ultraviolet curing type Lioduras (registered trademark) LCH2472RE (density: 1130 kg / m) manufactured by Toyochem Co., Ltd. ３ When this coating liquid is used, ultraviolet rays with a UV-A wavelength (320 to 400 nm) are irradiated at an integrated light intensity of 400 mJ / cm. ２ By irradiating the coating liquid in the above manner, the layer of the coating liquid can be hardened.

[0026] Next, the liquid reservoir suction portions 101 to 103 are cut off from the main body portion 100 of the dip-coated parts P1 to P3 (step S5). This forms the dip-coated product S. The liquid reservoir suction portions 101 to 103 are cut off from the main body portion 100 by cutting the notches 101b to 103b formed in the adjacent portions 101a to 103a of the liquid reservoir suction portions 101 to 103. The separation can be done by tearing them by hand or by using a tool such as a cutter.

[0027] The effects of this embodiment will be described.

[0028] (1) The dip-coated parts P1-P3 each include a main body 100 (product S), liquid reservoir suction sections 101-103 detachable from the main body 100, and a dip-coating layer L formed from the main body 100 to the liquid reservoir suction sections 101-103. The adjacent sections 101a-103a of the liquid reservoir suction sections 101-103 extend continuously along the edge 100a of the main body 100. The adjacent sections 101a-103a are connected to the edge 100a over their entire length. Therefore, by lifting the coating targets 11-13 from the coating liquid with the adjacent sections 101a-103a positioned below the main body 100, excess coating liquid can be more reliably sucked from the edge 100a of the main body 100. This makes it possible to prevent the formation of liquid pools near the edge 100a of the main body 100, and reduce variations in the thickness of the dip-coating layer L on the main body 100.

[0029] Furthermore, by separating the liquid pool suction portions 101-103 from the main body 100 after the dip coating layer L has dried, the main body 100, i.e., the component that will become the product S, can be easily formed. This improves productivity. Because the liquid pool suction portions 101-103 are integrally formed with the main body 100, there is no need to provide a complex mechanism, such as the coating liquid attracting member described in Patent Document 1, on the dipping device side. Even if the main body 100 has a complex shape, the adjacent portions 101a-103a of the liquid pool suction portions 101-103 can be formed to fit along the edge 100a where liquid pools may form. This reduces the variation in the thickness of the dip coating layer L formed on the surface 100A of the main body 100 without complicating the dipping device.

[0030] (2) The thickness of the adjacent portions 101a to 103a of the liquid pool suction portions 101 to 103 is smaller than the thickness of the edge 100a of the main body portion 100. This makes it easy to separate the liquid pool suction portions 101 to 103 from the main body portion 100. In particular, when notches 101b to 103b are formed as in this embodiment, the liquid pool suction portions 101 to 103 can be easily removed by bending them starting from the notches 101b to 103b.

[0031] In Example 2, the edge (fixed edge) of the adjacent portion 102a of the liquid pool suction portion 102 on the main body portion 100 side is connected to the center of the width of the end face of the edge 100a. This reduces the effect that the separation of the liquid pool suction portion 102 has on the dip coating layer L on the front surface 100A, which is the design surface of the product S. The notch 102b may be formed only on the front surface 102A side of the liquid pool suction portion 102, or on both the front surface 102A side and the back surface side.

[0032] (3) In this embodiment, a step is formed between the edge 100a of the main body 100 and the adjacent portions 101a to 103a. As shown in FIGS. 4 and 5, a liquid pool X with a concave surface is likely to form at the step. Because the liquid pool X has a greater depth than the surrounding layer of coating liquid due to the surface tension of the coating liquid, the flow resistance of the coating liquid inside the liquid pool X is smaller than the flow resistance inside the surrounding shallow layer. Because the liquid pool X formed at the step is formed near the edge 100a of the main body 100, it can promote the suction of coating liquid from the adjacent main body 100.

[0033] The above-mentioned effects (1) to (3) are achieved regardless of the orientation of the coating objects 11 to 13 when they are pulled up from the coating liquid. When the coating objects 11 to 13 were pulled up from the coating liquid, the following "vertical pulling" and "inclined pulling" methods were used. The coating liquid used was the ultraviolet-curable Lioduras (registered trademark) LCH2472RE manufactured by Toyochem Co., Ltd. The pulling speed was 1 mm / s.

[0034] In "vertical lifting," the objects to be coated 11-13 are moved upward in a vertical position in which the design surface of the main body 100 and the adjacent portions 101a-103a of the liquid reservoir suction portions 101-103 are parallel to the vertical direction, as shown in Figure 4. In "inclined lifting," the objects to be coated 11-13 are moved upward in a position in which the design surface of the main body 100 and the adjacent portions 101a-103a of the liquid reservoir suction portions 101-103 are inclined at 26.5° from the horizontal, as shown in Figure 5. In Figures 4 and 5, the object to be coated 14 is a comparative example in which no liquid reservoir suction portion is connected to the main body 100.

[0035] In the "vertical pull-up" method, as shown in Figure 4, the thickness of the dip-coating layer L on the main body 100 of the coating target objects 11 to 13, particularly on the surface 100A that serves as the design surface, is substantially uniform. No liquid pool X is formed on the surface 100A of the main body 100. On the other hand, on the surface of the coating target object 14, which is a comparative example, a liquid pool X is formed near the edge 100a.

[0036] In the "vertical pull-up" mode, the lower end of the curved portion 103c of the liquid pool suction portion 103 is inclined relative to the vertical direction, so that the liquid pool suction portion 103 can hold more coating liquid than the liquid pool suction portions 101 and 102. For example, in FIG. 4, relatively large liquid pools X are formed on the inside and outside of the curved portion 103c. Therefore, the liquid pool suction portion 103 can suck more excess coating liquid from the main body portion 100 than the liquid pool suction portions 101 and 102.

[0037] The liquid pool suction section 102 has a step formed between the surface 102A and the surface 100A of the main body section 100, and a liquid pool X is formed on this step. The liquid pool suction section 102 can hold more coating liquid near the edge 100a of the main body section 100 than the liquid pool suction section 101, which has a step formed only on the back surface side of the main body section 100. Therefore, in the "vertical pull-up", the liquid pool suction section 102 can suck more excess coating liquid from the main body section 100 than the liquid pool suction section 101.

[0038] In the "inclined pulling" method, as shown in FIG. 5, the thickness of the dip coating layer L on the main body 100 of the coating target objects 11 to 13, particularly on the surface 100A that serves as the design surface, is substantially uniform. No liquid puddle X is formed on the surface 100A of the main body 100. On the other hand, on the surface of the coating target object 14, which is a comparative example, a liquid puddle X is formed near the edge 100a. The size of the formed liquid puddle X is larger than the liquid puddle X formed in the "vertical pulling" method. The superiority of the coating target objects 11 to 13 over the coating target object 14 is more pronounced than in the "vertical pulling" method.

[0039] The surfaces 101A and 103A of the liquid pool suction sections 101 and 103 are flush with and continuous with the surface 100A of the main body section 100. A step is formed between the surface 102A of the liquid pool suction section 102 and the surface 100A of the main body section 100. In the "inclined pull-up" method, the component of gravity acting on the layer of coating liquid formed on the surface 100A of the main body section 100, which is parallel to the surface 100A, is smaller than in the "vertical pull-up" method, and the influence of the surface tension of the coating liquid is relatively greater than in the "vertical pull-up" method. Therefore, in the "inclined pull-up" method, the liquid pool suction sections 101 and 103 can suck more excess coating liquid from the main body section 100 than the liquid pool suction section 102.

[0040] <Modification of First Embodiment> Next, a modification of the first embodiment will be described with reference to Fig. 6. Fig. 6 is an enlarged side view of a main portion of the object 11 to be coated before dip coating. In this modification, a recessed groove, i.e., a notch 101b, is formed in the adjacent portion 101a along the edge 100a of the main body 100, and masking tape 101d is provided inside the notch 101b. The notch 101b is formed over the entire length of the adjacent portion 101a, and the masking tape 101d is provided over the entire length of the notch 101b.

[0041] (4) When the coating target 11 is pulled out of the coating liquid, a liquid puddle X is formed in the notch 101b, as shown in Figures 4 and 5. The liquid puddle X then hardens through drying or other processes. In this modification, the masking tape 101d is provided inside the notch 101b, which is a recessed groove. Therefore, prior to detaching the liquid puddle suction portion 101, the hardened liquid puddle X can be removed in advance by peeling off the masking tape 101d. This makes it easier to detach the liquid puddle suction portion 101 from the main body 100.

[0042] In this modification, masking tape 101d is used, but instead of or in addition to masking tape 101d, one or more of an adhesive layer, an adhesive rubber layer, and a water-repellent coating layer may be provided inside notch 101b, which is a recessed groove. This can promote peeling of hardened liquid puddle X from coating target 11 and more reliably remove liquid puddle suction part 101 from main body 100.

[0043] The masking tape, adhesive layer, adhesive rubber layer, and water-repellent coating layer (hereinafter referred to as masking tape, etc.) are not particularly limited. The adhesive layer can be formed, for example, by applying an acrylic adhesive, a silicone adhesive, a urethane adhesive, etc. to the wall surface inside the notch 101b. The adhesive rubber layer can be formed, for example, by attaching a sheet made of silicone rubber, fluororubber, urethane rubber, natural rubber, etc. to the inside of the notch 101b. An example of a silicone adhesive layer is a peelable silicone adhesive manufactured by Amon Kogyo Co., Ltd. An example of an adhesive rubber is BLU-TACK manufactured by Bostik. The water-repellent coating layer can be formed, for example, by attaching a fluororesin tape coated with the above adhesive to the inside of the notch 101b. An example of a fluororesin tape is fluororesin (PTFE) adhesive tape, NITOFLON No. 903UL, manufactured by Nitto Denko Corporation.

[0044] The same modifications as those described above can also be made to Examples 2 and 3. For example, in Example 2, masking tape or the like can be provided inside the notch 102b and / or inside the recessed groove formed on the surface 102A side (design surface side) of the adjacent portion 102a. In Example 3, masking tape or the like can be provided inside the notch 103b.

[0045] Each of the modified examples of Examples 1 to 3 has the configurations described in (1) to (3) above. Therefore, each of the modified examples of Examples 1 to 3 can also achieve the same effects as the first embodiment.

[0046] Second Embodiment A second embodiment will be described with reference to Figures 7 and 8. In the object 20 to be coated in this embodiment, the liquid reservoir suction portion 201 is configured to be detachable from the main body 200. That is, the liquid reservoir suction portion 201 is formed separately from the main body 200 and is attached to the main body 200 by an engagement mechanism described below before dip coating is performed. When the liquid reservoir suction portion 201 is attached to the main body 200, the adjacent portion 201a of the liquid reservoir suction portion 201 is in contact with the edge 200a of the main body 200 along its entire length.

[0047] The liquid pool suction portion 201 has the same thickness as the main body portion 200. The surface 200A, which is the design surface of the main body portion 200, and the surface 201A of the liquid pool suction portion 201 are flush and continuous. Like the coating target object 13, the liquid pool suction portion 201 has a curved portion 201c. The main body portion 200 also has a first engaging portion 210, and the liquid pool suction portion 201 has a second engaging portion 220 that can engage with the first engaging portion 210.

[0048] The first engagement portions 210 are provided near both ends of the edge 200a of the main body 200. Each first engagement portion 210 has four pillars 210a extending from the surface opposite the front surface 200A, which is the design surface of the main body 200, and a first engagement block 210b formed at the tip of the pillar 210a. A pair of engagement arms 210c extend parallel to each other in a direction perpendicular to the extension direction of the edge 200a from the first engagement block 210b. An engagement claw 210d is formed at the tip of each of the pair of engagement arms 210c, and the pair of engagement claws 210d protrude toward each other.

[0049] The second engagement portions 220 are provided near both ends of the adjacent portion 201a of the liquid pool suction portion 201. Each second engagement portion 220 has four pillars 220a extending from the liquid pool suction portion 201 and second engagement blocks 220b formed at the tips of the pillars 220a. The second engagement blocks 220b are engaged with a pair of engagement arms 210c extending from the first engagement block 210b. When the first engagement portion 210 and the second engagement portion 220 are engaged, the adjacent portion 201a of the liquid pool suction portion 201 comes into contact with the edge 200a of the main body portion 200 along its entire length.

[0050] In the second embodiment, when forming the dip-coated product S, steps S1 to S5 are performed as in the first embodiment. That is, the object to be coated 20 is immersed in the coating liquid with the first engaging portion 210 and the second engaging portion 220 engaged, and then the object to be coated 20 is lifted out of the coating liquid with the adjacent portion 201a positioned below the main body portion 200 and dried. In step S5, the first engaging portion 210 and the second engaging portion 220 of the dip-coated part are disengaged, thereby separating the reservoir suction portion 201 from the main body portion 200. Even if the main body portion 200 and the reservoir suction portion 201 become stuck together due to the dried coating liquid, the reservoir suction portion 201 can be separated at the interface with the main body portion 200 by making an incision with a cutter or the like in the gap between the edge 200a and the adjacent portion 201a. The first engaging portion 210 may be removed from the main body portion 200 using a tool such as a cutter.

[0051] (5) The dip-coated part of this embodiment includes a main body 200 that becomes the product S, a liquid reservoir suction portion 201 that can be separated from the main body 200, and a dip-coated layer L formed from the main body 200 to the liquid reservoir suction portion 201. The adjacent portion 201a of the liquid reservoir suction portion 201 extends continuously along the edge 200a of the main body 200. The adjacent portion 201a is connected to the edge 200a over its entire length. Therefore, the same effects as those described in (1) above can be obtained.

[0052] (6) In this embodiment, the liquid pool suction portion 201 is configured to be detachable from the main body portion 200, which makes it even easier to separate the liquid pool suction portion 201 from the main body portion 200. In particular, according to this embodiment, after the liquid pool suction portion 201 is separated, no part of the liquid pool suction portion 201 remains on the edge 200a of the main body portion 200, which makes it possible to omit or shorten processes such as deburring the edge 200a.

[0053] (7) In this embodiment, the main body 200 is provided with a first engaging portion 210, and the liquid pool suction portion 201 is provided with a second engaging portion 220 that can engage with the first engaging portion 210. When the first engaging portion 210 and the second engaging portion 220 are engaged, the adjacent portion 201a of the liquid pool suction portion 201 contacts the edge 200a of the main body 200 along its entire length. Therefore, by pulling the object to be coated 20 out of the coating liquid, excess coating liquid can be sucked not only by the liquid pool suction portion 201 but also by the first engaging portion 210 and the second engaging portion 220. This further reduces variation in the thickness of the dip coating layer L on the design surface of the main body 200.

[0054] <Modification of Second Embodiment> Next, a modification of the second embodiment will be described with reference to Fig. 9. Fig. 9 is a diagram of this modification, which corresponds to Fig. 8.

[0055] (8) In this modification, masking tape 201d is provided on the contact surface between the adjacent portion 201a of the liquid pool suction portion 201 and the edge 200a of the main body portion 200. This allows the liquid pool suction portion 201 to be more reliably separated from the edge 200a of the main body portion 200. Furthermore, because the masking tape 201d remains on the liquid pool suction portion 201 side after separation, the step of removing the masking tape 201d from the edge 200a of the main body portion 200 can be omitted.

[0056] In this modification, masking tape 201d is used, but instead of or in addition to masking tape 201d, one or more of an adhesive layer, an adhesive rubber layer, and a water-repellent coating layer may be provided on the contact surface of adjacent portion 201a with edge 200a. Even in this case, it is possible to more reliably separate liquid pool suction portion 201 from main body portion 200. The masking tape, etc., that is similar to that used in the modification of the first embodiment can be used.

[0057] This modified example has the configurations described in (5) to (7) above, and therefore can achieve the same effects as the second embodiment.

[0058] Third Embodiment A third embodiment will be described with reference to Figure 10. In the coating target 30 of this embodiment, as in the second embodiment, the liquid reservoir suction portion 301 is configured to be detachable from the main body 300. That is, the liquid reservoir suction portion 301 is formed separately from the main body 300 and is attached to the main body 300 by a connecting mechanism described below before dip coating is performed. When the liquid reservoir suction portion 301 is attached to the main body 300, the adjacent portion 301a of the liquid reservoir suction portion 301 is in contact with the edge 300a of the main body 300 along its entire length.

[0059] The liquid reservoir suction portion 301 has the same thickness as the main body portion 300. The surface 300A, which is the design surface of the main body portion 300, and the surface 301A of the liquid reservoir suction portion 301 are flush and continuous. The main body portion 300 is thicker than the main bodies 100, 200 of the objects 10, 20 to be coated. The main body portion 300 also has a connecting recess 310 formed in the edge 300a, and the liquid reservoir suction portion 301 has a connecting protrusion 320 formed in the adjacent portion 301a that fits into the connecting recess 310.

[0060] The connecting recesses 310 are provided near both ends of the edge 300a of the main body 300. Each connecting recess 310 is a rectangular parallelepiped hole formed in the end face of the edge 300a of the main body 300. The shape of the hole of the connecting recess 310 is not particularly limited, and may be cylindrical, polygonal prism, or the like.

[0061] The connecting protrusions 320 are provided near both ends of the adjacent portion 301a of the liquid reservoir suction portion 301. Each connecting protrusion 320 is a protrusion with a rectangular cross section that extends perpendicularly from the end face of the edge 300a of the main body portion 300. The shape of the connecting protrusions 320 corresponds to the shape of the connecting recesses 310, and the outer dimensions of the connecting protrusions 320 are the same as or slightly smaller than the inner dimensions of the connecting recesses 310. The cross-sectional shape of the connecting protrusions 320 is not particularly limited and may be cylindrical, polygonal, or the like.

[0062] In the third embodiment, when forming the dip-coated product S, steps S1 to S5 are performed as in the first and second embodiments. That is, the object 30 to be coated is immersed in the coating liquid with the connecting protrusion 320 fitted into the connecting recess 310, and then the object 30 is lifted out of the coating liquid with the adjacent portion 301a positioned below the main body 300, and dried. In step S5, the fitting between the connecting recess 310 and the connecting protrusion 320 of the dip-coated part is released, thereby separating the liquid reservoir suction portion 301 from the main body 300.

[0063] (9) The dip-coated part of this embodiment comprises a main body 300 that becomes the product S, a liquid reservoir suction portion 301 that can be separated from the main body 300, and a dip-coated layer L formed from the main body 300 to the liquid reservoir suction portion 301. The adjacent portion 301a of the liquid reservoir suction portion 301 extends continuously along the edge 300a of the main body 300. The adjacent portion 301a is connected to the edge 300a over its entire length. The liquid reservoir suction portion 301 is configured to be detachable from the main body 300. Therefore, the same effects as those described in (1) and (6) above can be obtained.

[0064] (10) In this embodiment, a connecting recess 310 is formed on the edge 300a of the main body 300, and a connecting protrusion 320 that fits into the connecting recess 310 is formed on the adjacent portion 301a of the liquid reservoir suction portion 301. When the connecting protrusion 320 is fitted into the connecting recess 310, the adjacent portion 301a of the liquid reservoir suction portion 301 contacts the edge 300a of the main body 300 along its entire length. According to this embodiment, no protrusions remain on the edge 300a of the main body 300 after the liquid reservoir suction portion 301 is separated, so a process for adjusting the outer shape of the main body 300, such as removing the protrusions, can be omitted. Furthermore, the connecting mechanism consisting of the connecting recess 310 and the connecting protrusion 320 has a simpler structure than, for example, the engagement mechanism of the second embodiment, and the amount of raw material (resin) can be reduced.

[0065] Fourth Embodiment A fourth embodiment will be described with reference to Figure 11. In the coating target 40 of this embodiment, as in the second and third embodiments, the liquid reservoir suction portion 401 is configured to be detachable from the main body portion 400. That is, the liquid reservoir suction portion 401 is formed separately from the main body portion 400 and is attached to the main body portion 400 by a bonding layer 402 (described below) before dip coating is performed. When the liquid reservoir suction portion 401 is attached to the main body portion 400, the adjacent portion 401a of the liquid reservoir suction portion 401 contacts the edge 400a of the main body portion 400 along its entire length via the bonding layer 402.

[0066] The bonding layer 402 is provided between the edge 400a of the main body 400 and the adjacent portion 401a of the liquid reservoir suction portion 401. The bonding layer 402 is composed of one or more of double-sided tape, adhesive, and adhesive rubber. The double-sided tape, adhesive, and adhesive rubber are not particularly limited as long as they maintain the bond between the main body 400 and the liquid reservoir suction portion 401 during immersion in the coating liquid and removal from the coating liquid, and allow the liquid reservoir suction portion 401 to be separated from the main body 400 after the coating layer dries. Examples of adhesives that can be used include acrylic adhesives, silicone adhesives, and urethane adhesives. Examples of adhesive rubbers that can be used include silicone rubber, fluororubber, urethane rubber, and natural rubber. Examples of double-sided tape that can be used include peelable double-sided tape manufactured by Scotch.

[0067] The bonding layer 402 is formed on the entire end surface of the edge 400a, as shown by dotted hatching in Figure 11. The bonding layer 402 may be formed on only a part of the end surface of the edge 400a, as long as it can maintain the bonded state between the main body 400 and the liquid reservoir suction portion 401. Although the bonding layer 402 is formed on the main body 400 in Figure 11, it may also be formed on the liquid reservoir suction portion 401, as long as it is interposed between the edge 400a and the adjacent portion 401a in the bonded state.

[0068] The liquid reservoir suction portion 401 has the same thickness as the main body portion 400. A surface 400A, which is the design surface of the main body portion 400, and a surface 401A of the liquid reservoir suction portion 401 are flush and continuous. The main body portion 400 is thicker than the main bodies 100 and 200 of the objects 10 and 20 to be coated.

[0069] When forming the dip-coated product S in the fourth embodiment, steps S1 to S5 are performed as in the first to third embodiments. That is, with the main body 400 and the liquid pool suction portion 401 bonded together by the bonding layer 402, the object 40 to be coated is immersed in the coating liquid, and then pulled out of the coating liquid with the adjacent portion 401a positioned below the main body 400, and dried. In step S5, the bond between the dip-coated part and the bonding layer 402 is released, thereby separating the liquid pool suction portion 401 from the main body 400.

[0070] (11) The dip-coated part of this embodiment comprises a main body 400 that becomes the product S, a liquid reservoir suction portion 401 that can be separated from the main body 400, and a dip-coated layer L formed from the main body 400 to the liquid reservoir suction portion 401. The adjacent portion 401a of the liquid reservoir suction portion 401 extends continuously along the edge 400a of the main body 400. The adjacent portion 401a is connected to the edge 400a over its entire length. The liquid reservoir suction portion 401 is configured to be detachable from the main body 400. Therefore, the same effects as those described in (1) and (6) above can be obtained.

[0071] (12) In this embodiment, a bonding layer 402 made of one or more of double-sided tape, adhesive, and adhesive rubber is provided between the edge 400a of the main body 400 and the adjacent portion 401a of the liquid pool suction portion 401. In the coating target 40, the adjacent portion 401a of the liquid pool suction portion 401 contacts the edge 400a of the main body 400 via the bonding layer 402 along its entire length. This makes it easier to separate the liquid pool suction portion 401 from the main body 400. Furthermore, after the liquid pool suction portion 401 is separated, no part of the liquid pool suction portion 401 remains on the edge 400a of the main body 400, and no holes like the connecting recess 310 are left behind. This eliminates the need for deburring or hole filling processes. Furthermore, the bonding layer 402 has a simpler structure than the engagement mechanism of the second embodiment or the connecting mechanism of the third embodiment, allowing for a reduction in the amount of raw material (resin).

[0072] (13) In all of the above embodiments and modifications, the dip-coated product S is formed by the following method. First, a part (object to be coated 11-13, 20, 30, 40) is formed (step S1) including a main body (100, 200, 300, 400) that will become the product S and a liquid reservoir suction part (101-103, 201, 301, 401) detachably connected to the main body. The adjacent parts (101a-103a, 201a, 301a, 401a) of the liquid reservoir suction part that are adjacent to the main body extend continuously along the edge (100a, 200a, 300a, 400a) of the main body. Next, the formed part is immersed in a coating liquid (step S2). Next, the immersed part is lifted out of the coating liquid with the adjacent part positioned below the main body (step S3: forming a coated part). The coating liquid layer formed on the lifted part is dried (Step S4). Finally, the liquid pool suction portion is separated from the main body (Step S5: Formation of the coated product S). This prevents liquid pools from forming near the edges of the main body and reduces the thickness variation of the dip coating layer L on the main body. Furthermore, by separating the liquid pool suction portion from the main body after the dip coating layer L has dried, the main body, i.e., the components that make up the product S, can be easily formed. This improves productivity. Furthermore, because the liquid pool suction portion is integrally formed with the main body, a complex mechanism such as the coating liquid attracting member described in Patent Document 1 is not required on the dipping device. Even if the main body has a complex shape, an adjacent portion of the liquid pool suction portion can be formed to fit along the edges where liquid pools may form. This reduces the thickness variation of the dip coating layer L formed on the surface of the main body without increasing the complexity of the dipping device.

[0073] The above-described embodiments are merely examples described to facilitate understanding of the invention. The technical scope of the invention is not limited to the specific technical matters disclosed in the above-described embodiments, but also includes various modifications, changes, alternative technologies, etc. that can be easily derived therefrom.

[0074] For example, in the above embodiments, the object to be coated was formed by additive manufacturing using a 3D printer, but the object to be coated may be formed by other methods, such as injection molding. Furthermore, in the above embodiments, the shape of the object to be coated was a flat plate or a rectangular parallelepiped with a rectangular outer shape, but the shape of the object to be coated can be selected appropriately to match the shape of the final product. For example, the main body portion may have a simple shape such as a curved plate, a cylinder, a block, or a rod, as well as a complex shape that is a combination of these. Furthermore, in the above embodiments, the shape of the edge on the main body portion side adjacent to each liquid reservoir suction portion was linear, but the shape of the edge may be curved, broken, wavy, or a combination of these.

[0075] P1 to P3 Dip-coated parts 100, 200, 300, 400 Main body 100a, 200a, 300a, 400a Edge 101 to 103, 201, 301, 401 Liquid reservoir suction portion 101a to 103a, 201a, 301a, 401a Adjacent portion 101b to 103b Notch (groove) 101d, 201d Masking tape 210 First engaging portion 220 Second engaging portion 310 Connecting recess 320 Connecting protrusion 402 Bonding layer L Dip-coated layer S Product

Claims

1. A dip-coated component, comprising: a main body that becomes a product; a liquid reservoir suction part detachably connected to the main body; and a dip-coating layer formed from the main body to the liquid reservoir suction part, wherein an adjacent part of the liquid reservoir suction part to the main body continuously extends along an edge of the main body, and the adjacent part is connected to the edge of the main body over its entire length.

2. The component according to claim 1, wherein a thickness of the adjacent part of the liquid reservoir suction part is smaller than a thickness of the edge of the main body.

3. The component according to claim 2, wherein a concave groove is formed along the edge of the main body in the adjacent part, and any one or more of a masking tape, an adhesive layer, an adhesive rubber layer, and a water-repellent coating layer are provided inside the concave groove.

4. The component according to claim 1 or 2, wherein the liquid reservoir suction part is configured to be detachable from the main body.

5. The component according to claim 4, wherein a first engaging part is provided on the main body, a second engaging part engageable with the first engaging part is provided on the liquid reservoir suction part, and in a state where the first engaging part and the second engaging part are engaged, the adjacent part of the liquid reservoir suction part contacts the edge of the main body over its entire length.

6. The component according to claim 5, wherein any one or more of a masking tape, an adhesive layer, an adhesive rubber layer, and a water-repellent coating layer are provided on a contact surface of the adjacent part with the edge.

7. The component according to claim 4, further comprising: a connecting concave part formed on the edge of the main body; and a connecting convex part formed on the adjacent part of the liquid reservoir suction part and fitting into the connecting concave part, and in a state where the connecting convex part fits into the connecting concave part, the adjacent part of the liquid reservoir suction part contacts the edge of the main body over its entire length.

8. The component according to claim 4, wherein a bonding layer made of any one or more of a double-sided tape, an adhesive, and an adhesive rubber is provided between the edge of the main body and the adjacent part of the liquid reservoir suction part, and the adjacent part of the liquid reservoir suction part contacts the edge of the main body through the bonding layer over its entire length.

9. A method for forming a dip-coated product, comprising a main body portion that becomes the product and a liquid reservoir suction portion detachably connected to the main body portion, wherein an adjacent portion of the liquid reservoir suction portion to the main body portion extends continuously along an edge of the main body portion, and the adjacent portion is connected to the edge of the main body portion over its entire length to form a component, dipping the component in a coating liquid, pulling the dipped component out of the coating liquid in a posture where the adjacent portion is positioned below the main body portion, drying a layer of the coating liquid formed on the component, and separating the liquid reservoir suction portion from the main body portion.

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