JPH10278054A - Transparent copy and method of making the same - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To produce a transparent duplicate product without using a mold and without having a material as strong as a metal, and a prototype product having at least a thin portion having a small thickness. However, the present invention provides a transparent duplicate product and a method for producing the same, which can almost certainly produce a transparent duplicate product including the thin portion. SOLUTION: A prototype female mold 20 having at least a part of an opaque and thin-walled thin portion is prepared, and at this time, a mold surface 19b of the female mold 20 corresponding to the thin portion of the prototype product.
A solid portion (convex portion) 30 penetrating the mold space between the mold surface and the opposed mold surface 18b is formed at approximately the center of the mold, and then the liquid state of the synthetic resin liquid having transparency is formed in the female mold 20. By injecting and solidifying the above material, a transparent duplicate of the original was produced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a transparent duplicate product of a small electrical product or the like whose material is not transparent and which is made of a transparent material.

[0002]

2. Description of the Related Art Conventionally, aluminum, magnesium, stainless steel, and the like have been used as materials for a housing or the like capable of achieving a required strength even with a small thickness while realizing miniaturization of portable and small electric appliances. A metal plate was used.

On the other hand, when such a small electric product is displayed in a showroom or a show window, or at the stage of prototyping the electric product, the above-mentioned housing is made transparent so that the inside can be visually recognized (visible) for internal confirmation. Because it may be advantageous to make the case out of a material, it may be required to make the case out of a transparent material, even if the case is actually made of an opaque material.

In such a case, conventionally, when the original product such as the above-mentioned housing is formed of an opaque synthetic resin, the actual opaqueness is obtained by using a molding die used for injection molding of the housing. Since the housing can be formed by injection molding using a transparent synthetic resin material instead of a simple synthetic resin material,
No problem.

As another method of forming a duplicate product such as a transparent housing without using a molding die, a transparent synthetic resin plate material such as an acrylic plate is dimensioned by cutting.
There is a method in which the corners are formed by bonding, and a method in which a transparent synthetic resin plate is heated and the corners are formed by pressing.

Further, there is a method of producing a transparent duplicate by a vacuum casting method. In this method, for example, a mold material such as silicon rubber is poured into a mold around the prototype to make a female mold, and after taking out the internal prototype, a transparent synthetic resin material is poured into the female mold. This is a method of creating a transparent duplicate.

[0007]

However, in such a conventional method for producing a transparent duplicate product, when the original product such as the housing is formed of an opaque synthetic resin, the same as described above. There is no problem since a molding die may be used. However, in the case where the prototype is a metal plate (sheet metal) housing or the like, there is no such a molding die as described above. Cannot be made in the same manner as in the case where is made of synthetic resin.

Therefore, even if a method of forming a housing by cutting or bonding using a transparent synthetic resin plate material such as an acrylic plate is used, a synthetic resin plate material having a thickness of 0.8 mm or less is cut. It is almost impossible in terms of strength to cut a block-like synthetic resin material down to a plate thickness equivalent to that of the metal plate of the housing to produce a plate material.

[0009] Even if a transparent plate having a thickness of 0.8 mm or less can be formed by shaving from a block of a synthetic resin material, such a transparent plate has a rough surface and reduced transparency due to cutting. If the surface is not polished, the desired transparency cannot be obtained. So even if you polish the surface,
The transparent plate may be damaged due to insufficient strength.

Further, when a method of heating and pressing a transparent synthetic resin plate material is used, only a large curve is obtained at the bent portion, and a case is provided in which a sharp R is provided and the corner is bent at a right angle. Can not.

Further, in the method of manufacturing by the vacuum casting method, since the female mold is formed of a material having elasticity, the mold surface 40a corresponding to the thin portion of the prototype is bent as shown in FIG. Female mold 4 to swell into mold space
Since the gap S in the space 0 becomes narrow or the mold surface 40a sticks to the opposed mold surface 40b, the liquid material of the transparent synthetic resin does not flow smoothly into the gap S and is filled with the material. There is almost no wall thickness formed in a portion that is supposed to be a thin portion, and there is a possibility that a large hole having a bad appearance such as a tear is formed in the thin portion.

In view of the above problems, the present invention makes it possible to produce a transparent duplicate without using a mold and without having a material having the strength of a metal, and to reduce the thickness of the prototype to a thin portion. An object of the present invention is to provide a transparent duplicate product and a method for producing the same, which can almost certainly produce a transparent duplicate product even if it has at least a part thereof, including its thin portion.

[0013]

In order to solve the above-mentioned problems, a method for producing a transparent duplicate product according to the present invention comprises producing a female mold of a prototype having at least a part of an opaque and thin-walled thin portion. At this time, a solid portion penetrating a mold space between the mold surface and a mold surface opposed to the mold surface is formed at a substantially central portion of a mold surface corresponding to the thin portion of the prototype, and then the female mold is formed. A transparent duplicate of the original product is produced by injecting and solidifying a liquid material of a transparent synthetic resin into the mold.

According to such a method for producing a transparent duplicate product, the female mold is provided with a mold space between the mold surface and the mold surface facing the substantially central portion of the mold surface corresponding to the thin portion of the original product. Since the solid part penetrating is formed, the solid part serves as a support to prevent the gap between the surrounding mold surfaces from being crushed, so that the mold surface corresponding to the thin portion of the female mold is bent and the mold is bent. Since the gap between the surfaces can be prevented from being narrowed or the mold surfaces from sticking to each other, the liquid material of the transparent synthetic resin smoothly flows into the gap between the mold surfaces in the mold and is filled. This makes it possible to form a transparent duplicate product including the thin-walled portion substantially in the same manner as the original product.

[0015]

Embodiments of the present invention will be described below in detail with reference to the drawings. 1 to 12
FIG. 1 is a diagram referred to for explaining a transparent duplicate product and a method for producing the same according to the present invention.

FIG. 1 is a view showing a housing 10 (original product) formed of a thin metal plate (sheet metal) having a thickness of 0.8 mm or less, with a bottom plate 10a arranged vertically. Is shown. A long hole 10b is formed in the center of the bottom plate 10a of the housing 10, and a female material to be described later and a liquid material to be described later are injected into an appropriate position on the lower side of the housing 10 in the drawing. A separate block 12 is bonded to form a gate (injection port).

The long hole 10b formed in the housing 10 as a prototype and the block 12 adhered to the housing 10 are provided for carrying out the present invention, and the housing 10 itself is originally intended. It is used for a part of electric products without the long hole 10b and the block 12. The housing 10 is usually formed of an opaque metal plate.

When the housing 10 is in the state shown in FIG. 1 and the preparation is completed, the block 12 is adhered to the bottom plate 14a in the mold 14 as shown in FIG. The silicone rubber 16 is poured into the mold 14. As the silicone rubber 16, a material obtained by mixing a main agent and a curing agent in advance and defoaming (foaming) in a vacuum is used.

Silicone rubber 1 poured into mold 14
6 further defoams in a vacuum and cures the silicone rubber 16 in a thermostat set at an appropriate temperature. After curing, the silicone rubber 16 is taken out of the thermostat, and as shown in FIG. 3, the center of the cured silicone rubber 16 in the thickness direction (left-right direction in the figure) is moved along the length direction and the height direction. By cutting using a knife 17 such as a scalpel for medical use,
The cavity 10 is divided into a cavity mold 18 and a core mold 19, and the casing 10 as a prototype is taken out from between the cavity mold 18 and the core mold 19.

Thereafter, the cavity mold 18 and the core mold 19
Is again placed in a thermostat, heated for several hours and subjected to secondary curing, whereby the cavity mold 18 and the core mold 19 as the female mold 20 are completed. A portion indicated by reference numeral 18a in FIG. 3 is a gate for injecting a liquid material described later.

The cavity mold 1 completed as described above
The release agent 22 shown in FIG.
Then, the cavity mold 18 and the core mold 19 are combined again, and the tape is integrated around the female mold 20 by taping. Then, it is again placed in a thermostat and heated to about 60 ° C.

Next, each process from the raw material of a transparent duplicated product to its completion will be described with reference to FIGS.

As shown in FIG. 5, a liquid base material A and a curing agent B which are raw materials of a transparent synthetic resin are respectively weighed, and as shown in FIG. Preliminary defoaming is performed in the vacuum chamber 24 for 30 minutes or more. And FIG.
As shown in Fig. 5, the liquid B of the curing agent is set in a stirrer, the liquid A of the main agent is added to the liquid B and mixed, and the mixture is stirred in the vacuum chamber 24 for 30 to 40 seconds ("mixing" in Fig. 5). Stirring ") After standing for 5 to 10 minutes, the mixture is occasionally stirred to remove bubbles.
The temperature of the mixture at this time is 35 to 50 ° C. In this way, a liquid C which is a liquid material of a transparent synthetic resin is completed.

Next, as shown in FIG. 8, a liquid C, which is a transparent synthetic resin material, is placed in a vacuum chamber 24 at a mold temperature of 60 ° C.
Gate (18a in FIGS. 3 and 4) in the mold of the female mold 20
(“Casting” in FIG. 5). Thereafter, vacuum defoaming is continued in the vacuum chamber 24, and then, as shown in FIG. 9, air is introduced into the vacuum chamber 24 to return the inside of the vacuum chamber 24 to atmospheric pressure ("leak" in FIG. 5). Cure the liquid (Fig. 5
"Curing").

Thereafter, the female mold 20 is taken out of the vacuum chamber 24, the taping of the female mold 20 is released, and the female mold 20 is divided into a cavity mold 18 and a core mold 19 as shown in FIG. The cured transparent synthetic resin is taken out ("demold" in FIG. 5). The transparent synthetic resin taken out at this time is placed in a block 2 corresponding to the block 12 of the housing 10.
7 (see FIG. 11), the block 27 is cut (removed) to complete the transparent duplicate 26. Finally, the release agent is washed away from the transparent duplicate 26 with a cleaning agent, and the process is completed.

In this manufacturing process, as shown in FIG. 12, the mold surface 18b of the cavity mold 18 of the female mold 20 is formed.
A gap S having the same size as the plate thickness of the housing 10 is formed between the metal mold 20 and the mold surface 19b of the core mold 19, but since the female mold 20 is formed of silicon rubber, a convex portion (solid) is formed. Part)
If no 30 is provided, as shown in FIG.
Either one or both of the mold surface 18b of the core mold 19 and the mold surface 19b of the core mold 19 are bent so as to swell.
The gap S becomes extremely narrow even if the contact surfaces 19b do not contact each other, or the contact surfaces 19b do not contact each other.
There is a possibility that the liquid C of the material of the transparent duplicate product 26 flows smoothly into the gap S between them and is not filled.

However, in the present invention, the core type 19
Since the convex portion 30 is formed at the center of the mold surface 19b, the convex portion 30 serves as a support to prevent the mold surfaces 18b and 19b from flexing so as to bulge. The liquid C can be spread throughout the inside.

The projections 30 of the core mold 19 are formed by previously forming an elongated hole 10b in the bottom plate 10a of the housing 10 so that the silicone rubber 16 enters the elongated hole 10b. , Female mold 20 to cavity mold 1
8 and the core mold 19 are formed so as to project from one of the core mold 19 side and the cavity mold 18 side, or to project from both sides and meet at an intermediate position of the gap S. Things. Protrusion of such protrusions 30 from the core mold 19 side is more excellent in terms of moldability and mold releasability.

When a hole similar to the long hole 10b is originally formed as a product at the center position of the bottom plate 10a of the housing 10, it is not necessary to open the long hole 10b in the bottom plate 10a of the housing 10. Needless to say. However, housing 10
Even if the bottom plate 10a originally has a hole as a product, if the hole is located relatively far from the center of the bottom plate 10a, a long hole 10b is formed separately from the hole at the center of the bottom plate 10a. Is more preferred.

As described above, the elongated hole 26a corresponding to the elongated hole 10b which does not exist in the original casing 10 is provided in the transparent duplicate product 2.
6, the transparent duplicate 26 cannot be said to be a complete duplicate of the housing 10, but since the purpose of making the duplicate is visual recognition of the inside of the housing 10, There is no particular hindrance, and it is transparent so it is not so noticeable.

FIG. 13 is a view showing a second embodiment of the present invention. In the first embodiment, the protrusion 30
Is integrally formed with the core mold 19 (or the cavity mold 18 or both), whereas in the second embodiment, the cavity mold 18 and the core mold 19 of the female mold 21 are formed. After that, a separate spacer 32 is sandwiched and formed between the cavity mold 18 and the core mold 19.

With this configuration, the first
It is possible to obtain exactly the same effects as those of the embodiment described above, and it is not necessary to make a long hole 10b in the housing 10 in advance. When the female mold 20 is divided into the cavity mold 18 and the core mold 19 as in the first embodiment, the protrusion 30
Before the silicone rubber 16 is poured, the long holes 10b opened in the housing 10 are separated from each other so as to remain on one side (or both sides) of the cavity mold 18 and the core mold 19. It is necessary to stick tape etc.,
According to the second embodiment, such labor can be omitted.

Although the embodiment of the present invention has been described with reference to the case where the original product is the housing 10 of a small electric product, the present invention is also applicable to products in other fields such as toys and small machinery. It is possible to

Further, even if only the housing is made transparent as in the above-described embodiment, there are cases where various parts such as badges, decorative plates, labels, etc. are attached to the surface or inner surface of the housing 10 in actual use. In such a case, when such a thing is attached to the transparent duplicate product 26, there is a possibility that the inside is difficult to be visually recognized. May be used as a prototype, and a female mold may be made by using the prototype. As a result, it is possible to make a transparent copy including other opaque parts other than the housing 10, thereby facilitating the visual recognition of the inside.

When a part or all of the surface of the original product has been subjected to processing such as shot blasting or hairline crease for functional or decorative purposes, the material itself of the duplicate product is transparent. However, such a processed portion cannot provide sufficient transparency, but in such a case, the transparency can be improved by applying a transparent synthetic resin paint to the surface of the processed portion.

[0036]

As described above, according to the present invention,
Since a solid part penetrating the mold space between this mold face and the opposite mold face was formed at the approximate center of the mold face corresponding to the thin part of the original product, the solid part became a support Then, by preventing the gap between the surrounding mold surfaces from being crushed, the mold surface corresponding to the thin portion of the female mold is bent to narrow the gap between the mold surfaces, or the mold surfaces are stuck together. Liquid material of a transparent synthetic resin can smoothly flow into and fill the gap between the mold surfaces in the mold, and the transparent replicated product including the thin portion can be substantially formed. It can be formed in the same manner as a prototype.

Therefore, according to the present invention, it is possible to produce a transparent duplicate even if the original is an extremely thin product. Therefore, according to the present invention, the internal state of the device covered by the metal housing that cannot be visually recognized inside can be visually recognized.

Further, since a cutting step is not included in the process of producing the female mold and other processes for producing the transparent duplicate product, the smoothness of the surface of the transparent duplicate product is not impaired than the smoothness of the original product. Good replicas can be created.

Further, even when various parts are attached to the original product casing, a female mold can be made with these components attached, and a transparent duplicate product can be made. It is possible to prevent the transparency of the transparent duplicate from being impaired by various components.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a housing 10 as a prototype product prepared for carrying out a first embodiment of a transparent duplicate product and a method for producing the same according to the present invention.

FIG. 2 is a perspective view showing a state where a female mold of the housing 10 of FIG. 1 is formed.

FIG. 3 is a perspective view illustrating a state in which a female mold 20 including a cavity mold 18 and a core mold 19 is formed.

FIG. 4 is a perspective view showing a state in which a mold release agent 22 is applied to the mold forming surfaces of the cavity mold 18 and the core mold 19, and then the cavity mold 18 and the core mold 19 are combined to form the female mold 20.

FIG. 5 is a flowchart showing each step from the raw material of a transparent duplicate product to completion.

FIG. 6 is a schematic cross-sectional view showing a state in which a raw material of a transparent duplicate is vacuum degassed in a vacuum chamber 24.

FIG. 7 is a schematic cross-sectional view showing a state in which raw materials for a transparent duplicate product are vacuum degassed while being mixed and stirred in a vacuum chamber 24.

FIG. 8 is a schematic cross-sectional view showing a state in which a liquid material of a transparent duplicate is injected into the female mold 20 while defoaming in a vacuum chamber 24 under vacuum.

FIG. 9 is a schematic cross-sectional view showing a state in which air is introduced into the vacuum chamber 24 to cure the liquid material of the transparent duplicate after the step shown in FIG.

FIG. 10 is a perspective view showing a state in which the female mold 20 is divided in order to take out a cured transparent duplicate product from the inside of the female mold 20.

FIG. 11 is a transparent duplicate product 2 taken out of the female mold 20.
It is a perspective view which shows 6.

FIG. 12 is a cross-sectional view showing a gap S in a female mold 20 in which a cavity mold 18 and a core mold 19 are combined.

FIG. 13 is a cross-sectional view of a female mold 21 showing a second embodiment of the present invention.

FIG. 14 shows a mold surface 40 of a female mold 40 according to a conventional vacuum casting method.
It is sectional drawing which shows the state which "a" bent.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... housing | casing, 10a ... bottom plate, 10b ... long hole, 12 ... block, 14 ... mold frame, 14a ... bottom plate, 16 ... silicon rubber, 17 ... blade tool, 18 ... cavity type, 18a ... gate, 18b ... mold surface , 19: core type, 19b: mold surface, 2
0, 21 ... female type, 22 ... release agent, 24 ... vacuum chamber, 26 ...
Transparent copy, 26a ... long hole, 27 ... block, 30 ... convex, 32 ... spacer, 40 ... female mold, 40a, 40b ...
Mold surface, S ... gap

Claims (6)

[Claims] 1. A female mold of a prototype having at least a part of an opaque and thin-walled thin part is prepared, and at this time, a substantially central part of a mold surface of the female die corresponding to the thin part of the prototype is formed. By forming a solid portion penetrating the mold space between this mold surface and the opposite mold surface, and then injecting and solidifying a liquid material of a synthetic resin having transparency into the female mold, A method for producing a transparent duplicate, wherein a transparent duplicate of the prototype is produced. 2. The female mold is formed after a hole is formed in a substantially central portion of a thin portion of the prototype, and at this time, the material of the female mold enters the hole, whereby the solid is inserted into the female mold. 2. The method according to claim 1, further comprising forming a portion. 3. After forming the female mold without making a hole substantially in the center of the thin portion of the prototype, the position of the female mold in the approximate center of the mold surface corresponding to the thin portion of the prototype. 2. The transparent duplicate product according to claim 1, wherein the solid portion is formed by adding a spacer having the same height as a dimension between the mold surface and the opposite mold surface. Method. 4. The transparent mold according to claim 1, wherein the female mold is formed in a vacuum, and / or a synthetic resin material having transparency is injected into the female mold in a vacuum. How to make a duplicate. 5. The method according to claim 1, wherein a transparent synthetic resin paint is applied to the surface of the portion having low transparency due to the shape and roughness of the surface of the transparent duplicate. Method. 6. A female mold of a prototype having at least a part of an opaque and thin-walled thin portion is formed, and at this time, a substantially central portion of a mold surface of the female die corresponding to the thin portion of the prototype is formed. A solid portion is formed through the mold space between the mold surface and the opposite mold surface, and then a liquid material of a synthetic resin having transparency is injected into the female mold and solidified. A transparent reproduction product characterized by being performed.