JP7361161B2 - Model parts and method for manufacturing model parts - Google Patents

Description

The present invention relates to a model component and a method for manufacturing the model component.

When coloring parts (also referred to as parts) of an assembled model such as a so-called plastic model (registered trademark), for example, the face of a toy, the color is painted one by one by hand, or the painted parts are painted one by one. Spray painting using a mask provided with openings has been practiced (see Patent Document 1). Furthermore, a method has been proposed in which painting is automated using a coloring device equipped with a plurality of printing machines and a conveyor (see Patent Document 2).

Publication number 3-34226 Japanese Patent Application Publication No. 8-47585

However, it requires skill to create a gradation in which the color gradually becomes darker, and it is difficult to stabilize the quality. Furthermore, when using a coloring device for painting, there are also problems in that additional capital investment is required and the equipment becomes larger.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a model component that is gradated with stable quality and a method for manufacturing the same.

The present invention for solving the above problems is a model component,
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, and a second layer made of a second material of a second color different from the first color. A model part,
The second layer is configured to include a first part where the first layer is visible and a second part which is continuous with the first part and where the first layer is not visible. .
The present invention also relates to a model component,
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, and a second layer made of a second material of a second color different from the first color. A model part,
The second layer includes a first portion where the first layer is visible through the second layer and a second portion where the first layer is not visible through the second layer. It is composed of
The first portion is formed to include a portion thinner than a first thickness at which the first color passes through the second material and becomes visible from the outside of the model component.

According to the present invention, it is possible to provide a model component on which gradation is applied with stable quality and a method for manufacturing the same.

1 is a flowchart illustrating an example of a method for manufacturing a model component according to an embodiment of the invention. FIG. 3 is a diagram for explaining the structure of a model component corresponding to an embodiment of the invention. FIG. 3 is a diagram for explaining a cross-sectional structure of a model component corresponding to an embodiment of the invention. It is a figure for explaining the molded object produced according to the manufacturing method of the model part corresponding to the embodiment of the invention.

Hereinafter, exemplary embodiments of the invention will be described with reference to the drawings. Note that in each figure, the same reference numerals indicate the same elements. In addition, in each figure, the up, down, left and right directions with respect to the plane of the paper will be used as the up, down, left and right directions of the component (or parts) in this embodiment in the description in the main text. Although polystyrene is used as an example of the molding material in the embodiments described below, the present invention is not limited to this, and other materials (polyethylene, thermoplastic resins such as ABS, thermosetting resins, metals, etc.) may also be used. It does not exclude.

First, a method for manufacturing a model component according to an embodiment of the invention will be described according to the flowchart in FIG. In S101, primary molding is performed to form a primary molding layer that constitutes the skeleton portion of the model component. Reinforced polystyrene (KPS) can be used as a molding material (raw material) for the primary molding layer. Next, in S102, secondary molding is performed to form a secondary molding layer above the primary molding layer so as to cover the primary molding layer. As a molding material for the secondary molding layer, for example, general purpose polystyrene (GPPS) or high impact polystyrene (HIPS) can be used. In subsequent S103, tertiary molding is performed to form a tertiary molding layer above the secondary molding layer so as to cover the secondary molding layer. As the molding material for the tertiary molding layer, the same KPS as for the primary molding layer can be used. The tertiary molding layer forms the outer surface of the model part, but its thickness differs in some parts, and the thinner parts are different in color from the secondary molding layer formed underneath. It is made so thin that it can be seen through.

In the above process, the molding materials constituting the primary molding layer and the tertiary molding layer are of the same type and color. On the other hand, the molding material of the secondary molding layer is at least different in color compared to the molding materials of the primary molding layer and the tertiary molding layer. The secondary molding layer can have a higher color density than the primary molding layer and the tertiary molding layer. For example, when a model part constitutes a part of a doll's face or body, the tertiary molding layer that makes up the surface is skin-colored, while the secondary molding layer is dark skin-colored, deep orange, or It can be dark pink or the like. The color of the tertiary molding layer and the color of the secondary molding layer may be similar colors, or may be similar colors or opposite colors to each other. In this embodiment, the tertiary molding layer and the secondary molding layer are formed using molding materials of different colors, the tertiary molding layer is formed thinly on top of the tertiary molding layer, and the secondary molding layer of a different color underneath is formed. By making the layers transparent, it is possible to express gradations.

Moreover, the material of the molding material of each molding layer can be made of a common material because the primary molding layer, the secondary molding layer, and the tertiary molding layer are bonded to each other and integrated. In the above example, although KPS, GPPS, and HIPS have different properties, they all use a common material, polystyrene. In addition to polystyrene, for example, ABS resin or polyethylene (PE) may be used in common. Further, different materials may be used for some of the layers.

The method for manufacturing a model component that includes the three-step molding process described above can be carried out using, for example, a multicolor molding device. Each molding process uses a mold corresponding to that process. Specifically, a molded product is formed by flowing a molding material into a runner groove of a mold and a molding space (cavity) for molding each component, and after cooling, the molded product is taken out from the mold. The molded articles produced by primary molding and secondary molding are attached to molds for the next molding process, respectively, and secondary molding or tertiary molding is performed. Since the molding method itself using the multicolor molding device is well known, a more detailed explanation will be omitted.

FIG. 2 is a diagram for explaining an example of the structure of a model component manufactured according to the manufacturing method shown in FIG. FIG. 2(A) is a diagram showing an example of a model part 200 as a part of the body of a doll toy, produced by a three-step molding process corresponding to this embodiment. FIG. 2(B) is an exploded view of the model component 200 separated from the primary molding layer to the tertiary molding layer. As shown in FIG. 2(B), the primary molding layer 201 forms a skeleton portion of the fuselage. This skeleton has a comb-like or lattice-like structure with gaps between the members, but this structure is just an example, and the entire skeleton may be filled with molding material without gaps.

The secondary molding layer 202 is formed to cover the primary molding layer 201, and has an uneven surface formed thereon, and the thickness of the tertiary molding layer 203 is adjusted by the unevenness. The tertiary molding layer 203 is a molding layer that forms the surface of the model, and has a surface that corresponds to the desired external shape of the model. Since the model part 200 is a part of the body of the toy doll, the line of the abdominal muscles, the constriction of the waist, etc. are expressed by the surface shape of the tertiary molded layer.

Comparing the secondary molding layer 202 and the tertiary molding layer 203, the secondary molding layer 202 has a part that is similar in shape to the tertiary molding layer 203 (a shape obtained by reducing the size of the tertiary molding layer 203) and a part that is not similar in shape. It is configured to include. In the similar-shaped portion of the secondary molding layer 202, the thickness of the tertiary molding layer 203 is maintained at a predetermined value. On the other hand, the portions that are not similar in shape are more protruding (forming a convex shape) than the portions in the similar shape, and as a result, the tertiary molded layer 203 is formed to be thinner than a predetermined value. Here, the predetermined value corresponds to the thinnest thickness of the tertiary molding layer at which the color of the secondary molding layer is no longer visible from the outside after passing through the tertiary molding layer.

Next, the cross-sectional structure of the model component 200 corresponding to this embodiment will be explained. FIG. 3(A) is a cross-sectional view exemplarily showing the AB cross section of the model component 200 in FIG. 2(A). As shown in the cross-sectional view of FIG. 3(A), it can be seen that the thickness of the tertiary molded layer 203 that constitutes the outermost surface of the model component 200 differs depending on the location of the model component 200. For example, when comparing the thicknesses D1, D2, and D3, D1>D2≈D3. Here, it is assumed that D1 has the thinnest thickness (corresponding to the above-mentioned predetermined thickness) in a region where the secondary molding layer 202 cannot be seen through the surface of the tertiary molding layer 203. Moreover, D2 and D3 each have the thickness of the thinnest part in the region where the secondary molding layer 202 is visible from the surface of the tertiary molding layer 203. D2 and D3 need only be thinner than a predetermined thickness of D1.

In this embodiment, the numerical values of D1, D2, and D3 can be set to D1=d1 (eg, 1 mm) and D2=D3=d2 (eg, 0.5 mm), respectively. However, this is just an example, and the values of d1 and d2 may be smaller or larger depending on the properties (transparency) of the material used. Alternatively, if it is desired to change the degree of transparency of the base depending on the location, the thinnest value within the region may be set to a different value. For example, D2 may be 0.5 mm and D3 may be 0.7 mm.

By forming the tertiary molding layer 203 partially thin in this way, the color of the secondary molding layer 202 located inside the tertiary molding layer 203 can be observed from the outside of the model part 200 by passing through the tertiary molding layer 203. becomes possible. FIG. 3B is a diagram for explaining a case where the color of the secondary molding layer 202 becomes observable from the outside of the model part 200 through the tertiary molding layer 203. As shown in FIG. 3(B), the transmission region 204 is formed at a position where the thickness of the tertiary molding layer 203 is reduced.

At this time, as the thickness of the tertiary molding layer 203 changes from the thinnest value d2 to d1 where the base is no longer visible, the transparent area 204 is darkest at the thinnest value, and the color of the base secondary molding layer 202 is the same. Since the color gradually becomes lighter from the transparent portion and changes to the color of the tertiary molded layer 203 itself, the viewer can observe the gradation on the surface of the model part 200.

The appearance of the gradation can be made different depending on how the change is made from d2 to d1. For example, depending on whether the degree of thickness change is steep or gradual, the way the color changes from a dark color to a light color differs, so different gradation expressions can be realized. For example, if you want to produce a partially dark color, the change from d2 to d1 may be made steep. On the other hand, if it is desired to transition from a dark color to a light color to the material color of the tertiary molded layer 203, the change from d2 to d1 is made gradual. For example, if we assume that in a circular area centered at a position with a thickness d2, the thickness increases in the radial direction from the center, and the thickness becomes d1 at a position at a radius r from the center, the radius If the radius r is increased, the change will be gradual, and if the radius r is decreased, the change will be steep.

Further, if the molding material is the same, the value of d1 is fixed, but the value of d2 can be made variable, so the value of d2 may be changed depending on the aspect of the gradation desired to be expressed. If the color to be expressed in the area to which the gradation is to be added may be lighter than the darkest value, the value of d2 can be set to 0.7 mm instead of 0.5 mm, for example.

Next, with reference to FIG. 4, the structure of a molded product formed by sequentially molding from the primary molding layer to the tertiary molding layer according to the molding method shown in FIG. 1 corresponding to this embodiment will be described. FIG. 4(A) is a diagram showing an example of a molded article 400 formed by primary molding. FIG. 4(B) is a diagram showing an example of a molded article 410 formed by secondary molding. FIG. 4(C) is a diagram showing an example of a molded article 420 formed by tertiary molding.

In the primary molding of S101 in FIG. 1, a molded article 400 is first produced. The molded product 400 is composed of a main runner 401, a sub runner 402, and a part 403. The molded article 400 is made of reinforced polystyrene (KPS). The main runner 401 is formed to surround the component 403, and the component 201 is fixed to the main runner 401 by being connected to the main runner 401 via the sub-runner 402. The main runner 401 and the sub-runner 402 correspond to grooves for causing molding material to flow into a cavity corresponding to a part 403 in a first molding die (usually consisting of a male mold and a female mold) (not shown). . In the primary forming of S101, the molding material (KPS) is flowed into the cavity corresponding to the part 403 from the main runner groove of the first mold through the sub-runner groove, and the molding material (KPS) is flowed into the cavity, the main runner groove and the sub-runner groove. The molded article 400 can be produced by filling all of the molding material with the molding material and cooling it.

Next, in secondary molding in S102, a molded article 410 is produced. Molded article 410 is formed by covering at least a portion of molded article 400 with general purpose polystyrene (GPPS) or high impact polystyrene (HIPS). The molded article 410 includes a main runner 411, a sub-runner 412, and a component 413 in addition to the molded article 400. In this embodiment, the component 413 is formed by forming GPPS or HPPS on the surface of the component 403 from the main runner 411 to the sub-runner 412. The main runner 411 is fixed to the main runner 401 by connecting with the sub runner 402. Moreover, the component 413 is fixed to the main runner 401 via the main runner 411 by being connected to the main runner 411 via the sub-runner 412 .

Similar to the main runner 401 and the like, the main runner 411 and the sub runner 412 correspond to grooves for causing a molding material to flow into a cavity corresponding to a component 413 in a second mold (not shown). In the secondary molding of S102, after the molded product 400 is fixed in the second mold, the molding material ( The molded product 410 can be produced by flowing the molding material (GPPS or HIPS) and filling the molding material into the cavity, the main runner groove, and the auxiliary runner groove, and then cooling the molded material.

Note that when performing secondary molding, runner grooves are placed only above and below the component 413. This is due to the following reasons. First, the part 413 is a part of the doll's body, and the upper and lower parts are configured to be connected to other parts. Therefore, the upper and lower surfaces that correspond to the connecting surfaces are not exposed to the surface of the finished doll toy. In contrast, the sides are the doll's body itself and will be exposed on the surface of the finished doll toy. At that time, if the connecting part with the sub-runner remains on the side, it will affect the appearance of the finished product. Therefore, when molding the molded product 410 by secondary molding, the runner grooves are arranged so that the molding material is supplied from a direction that does not affect the appearance of the finished product.

Next, in tertiary molding in S103, a molded article 420 is produced. Molded article 420 is formed by covering at least a portion of molded article 410 with KPS. The molded product 420 includes a main runner 421, a sub-runner 422, and a component 423 in addition to the molded product 410. The surface of the molded product 420 will be covered with KPS, but it is only necessary that at least the exposed surface of the finished doll toy be covered with KPS, and it is not necessary that the entire molded product 420 be covered with KPS. do not have.

Main runner 421 is formed to surround component 423 . In FIG. 4C, the main runners 421 surround the periphery, but the main runners 421 may be provided only on the left and right sides. Part 423 is connected to main runner 421 via sub runner 422 . In FIG. 4C, since the molded product 420 is viewed from the front side, there are some parts where the connection between the sub-runner 422 and the component 423 is hidden behind the sub-runner 402 and is not shown. The sub runner 422 and the component 423 are connected on the back side of the sub runner 402. Further, the sub runner 422 is connected to the main runner 401 or the sub runner 402, and the component 423 is fixed to the main runner 401 by this connection.

Similar to the main runner 401 and the like, the main runner 421 and the sub runner 422 correspond to grooves for causing molding material (KPS) to flow into a cavity corresponding to a component 423 in a third mold (not shown). . In the tertiary molding of S103, after the molded product 410 is fixed in the third mold, the molding material is poured into the cavity corresponding to the part 423 from the main runner groove of the third mold through the sub-runner groove. The molded article 420 can be produced by flowing the molding material into the cavity, the main runner groove, and the auxiliary runner groove, and then cooling the molding material.

Through the above steps, the molded article 420 can be molded. As shown in FIG. 4(C), all that are connected to the side surface of the molded product 420 are KPS sub-runners, and there are no GPPS or HPPS sub-runners on the side surface; Only exists. Therefore, no traces of connection with the GPPS or HPPS material runner remain on the body surface of the finished doll toy.

In the above description of the embodiment, a method was described in which a portion corresponding to the skeleton of the part is first formed by primary molding, and then secondary molding and tertiary molding are performed. However, embodiments of the invention are not limited to this procedure. For example, for locations where it is not necessary to produce a skeleton part, primary molding may be omitted and secondary molding may be started.

It is considered necessary to produce a skeleton when producing a part such as the fuselage described in the above embodiment, in which the material for secondary molding cannot be exposed on the surface. For example, in the case of a doll toy, the surfaces of parts such as the torso, arms, and legs are expected to be exposed, so a skeleton is created for such parts to ensure that they are fixed to the runner. If a skeleton is not created for such a part, the main runner and sub runner will be formed only by the secondary molding layer created in the secondary molding, and the parts before tertiary molding will be formed by the secondary molding layer created in the secondary molding. Only the runner will be connected to the main runner. In the secondary molding layer, the injection direction of the molding material is limited so that the connection part of the runner is not exposed on the surface of the doll toy, so the connection to the main runner is weak, and the injection pressure when molding the tertiary molding material is may not be able to withstand it. In addition, if the skeleton is not produced, the parts will be connected in the left-right direction of the main runner by the sub-runner produced in tertiary molding. In this case, the tertiary molding layer produced in tertiary molding is thin, and the connection part is made as thin as possible so as not to leave any connection marks on the part surface, so the strength of the connection part between the part and the sub-runner is relatively weak. This makes it difficult to securely fix the molded product to the runner. On the other hand, if the skeleton is created by primary molding, the connection between the parts and the sub-runner will pass through the secondary molding layer and the tertiary molding layer to ensure the connection of the parts. , the strength of the connection part can be increased. At this time, if the molding materials constituting the primary molding layer and the tertiary molding layer are made of the same color as in this embodiment, the connecting portion between the skeleton parts formed by the primary molding and the sub-runner Even if it penetrates the tertiary molding layer, since it is the same color, it will be difficult to stand out, which is preferable in terms of improving the appearance of the finished product.

For the above reasons, it is desirable to perform primary molding for parts where exposure of the secondary molded layer on the surface of the finished product should be avoided. On the other hand, parts that are exposed on the surface but are covered and hidden by other parts and are not exposed as a result, such as the face of a doll toy, can be hidden at the end by hair parts. , the primary molding may be omitted and the secondary molding may be started. In addition, even if the arm or torso includes a part that is not exposed to the surface by attaching a separate accessory, it is possible to ensure connection with the runner in the part that is hidden by the accessory. The subsequent molding may be omitted.

Moreover, although the case where the color of the material used in secondary molding is one color has been described, materials of multiple colors may be used in layers. For example, in the above-described embodiment, the color of the tertiary molding layer forming the surface of the doll toy is skin tone, and the color of the secondary molding layer is orange or pink. A black layer may be further formed under the secondary molding layer. At this time, by adjusting the thickness of the layer in the same manner as in the above embodiment, the manner in which shading is provided can be adjusted.

As described above, according to the present embodiment, it is possible to provide a model component with a gradation of stable quality and a method for manufacturing the same.

Claims (13)

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, and a second layer made of a second material of a second color different from the first color. A model part,
The second layer includes a first portion where the first layer is visible through the second layer and a second portion where the first layer is not visible through the second layer. It is composed of
The first part is formed to include a part thinner than a first thickness in which the first color passes through the second material and becomes visible from the outside of the model part. parts. The model component according to claim 1, wherein the first color has a higher density than the second color. 3. The model component according to claim 1, wherein the first color and the second color are similar colors, similar colors, or colors that are opposite to each other. 4. The method according to claim 1 , wherein the second layer is formed so as to change from a second thickness thinner than the first thickness to the first thickness in the first portion. The model component according to any one of the items . The model component according to claim 4 , wherein the second thickness is half the first thickness. The model component includes a runner for fixing the model component and the second layer on a surface that constitutes the appearance of the finished product when the model component is combined with other model components to configure the finished product. The model part according to any one of claims 1 to 5 , wherein the model parts are connected to each other. 7. The model component according to claim 6 , wherein the first layer connects to a runner on a surface that does not constitute an appearance of the finished product when the model component composes the finished product. The model component according to any one of claims 1 to 7 , further comprising a third layer covered with the first layer. 9. The model component according to claim 8 , wherein the third layer connects to a runner on a surface that constitutes the appearance of the finished product when the model component is combined with other model components to configure a finished product. The model component according to claim 8 or 9 , wherein the third layer has a third color different from the first color or the second color. The model component according to any one of claims 8 to 10 , wherein the third layer includes a portion that is visible through the first layer and the second layer. A method for manufacturing model parts, the method comprising:
a first step of molding a first layer using a first material of a first color;
a second step of forming a second layer using a second material of a second color different from the first color so as to cover at least a portion of the first layer,
In the second step, the second layer has a first part where the first layer is visible through the second layer and a second part where the first layer is not visible through the second layer. 2 parts ,
The first portion is formed to include a portion thinner than a first thickness in which the first color passes through the second material and becomes visible from the outside of the model component. Further comprising a third step of molding a third layer made of the second material before the first step,
In the first step, the first layer is formed to cover the third layer,
In the first step, when the model part is combined with other model parts to form a finished product, the first material is applied from a direction corresponding to a surface of the model part that does not constitute the appearance of the finished product. provided,
In the second step and the third step, when the model component is combined with other model components to configure a finished product, a direction corresponding to a surface of the model component that constitutes the appearance of the finished product is determined. 13. The manufacturing method according to claim 12 , wherein the second material is provided from a direction including.

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