WO2018092732A1 - Resin molding device and resin molding method - Google Patents

Abstract

The present invention provide a resin molding device and a resin molding method, wherein all thermoplastic resins can be used by using a resin mold formed by three-dimensional shaping and by injecting a product resin material into the resin mold. This resin molding device is provided with: a stage; a storage tank installed on the stage; an energy beam irradiation part which emits an energy beam; an injection part which plasticizes a first material, which is a synthetic resin, and injects the first material through an injection port; and a drive means which enables three-dimensional movement of the stage, the energy beam irradiation part and the injection part relative to each other. The storage tank is provided therein with a table which can be driven at least in the gravitational direction, and a liquid curable resin material, including an energy beam-curable resin which is cured by the energy beam, is stored in the storage tank.

Description

Resin molding apparatus and resin molding method

The present invention relates to a resin molding apparatus and a resin molding method.

Conventionally, there has been known a method of obtaining a desired three-dimensional molded product by using an ultraviolet curable resin for forming a three-dimensional molded product and sequentially laminating cured layers cured in a layer form by ultraviolet rays (Patent Document 1). Patent Document 1 discloses that a dummy hardened layer is formed in advance in a continuous manner under the branch when forming a branch that does not reach the lower end of the three-dimensional molded product. It is said that an accurate three-dimensional molded product can be obtained.

However, in the method of obtaining the three-dimensional molded product disclosed in Patent Document 1, it is necessary to add a portion corresponding to the dummy hardened layer from the design stage, and further, after the three-dimensional molding, the dummy mold is used. It is necessary to remove the cured product. Therefore, a hot melt type ink containing different types of resin materials having different melting points is ejected from an inkjet head, and a desired three-dimensional molded product formed of a high melting point ink and a desired three-dimensional shape of a low melting point ink. A method is disclosed in which a single layer in a region other than a molded product is formed, and the single layer is laminated to form a solid (Patent Document 2).

In the method disclosed in Patent Document 2, the low melting point ink is melted and removed from the formed solid by heating at a temperature higher than the melting point of the low melting point ink and lower than the melting point of the high melting point ink. can do. Thereby, the desired three-dimensional molded product formed with the high melting point ink can be obtained.

JP-A-2-251419 JP-A-9-123290

However, in the method for forming a three-dimensional molded product disclosed in Patent Document 1 and Patent Document 2, there are limitations on materials that can be applied. In Patent Document 1, a material that can be cured by an energy beam including ultraviolet rays must be used. In Patent Document 2, a hot melt type ink is required to be a resin material that can be discharged and supplied from an inkjet head.

Further, in recent modeling of a three-dimensional molded product (hereinafter referred to as 3D modeling), a three-dimensional molded product in which desired quality, for example, strength, heat resistance, chemical resistance, and the like can be obtained by 3D modeling is not limited to modeling of a desired shape. It has come to be required. Therefore, the method for forming a three-dimensional molded product disclosed in Patent Document 1 and Patent Document 2 is applied to a prototype or a product that requires a material that cannot be cured by an energy beam or an extremely low melting point material. It was difficult to do.

Therefore, there are provided a resin mold by 3D modeling, and a resin molding apparatus and a resin molding method capable of using any thermoplastic resin by injecting a product resin material into the resin mold.

The present invention has been made to solve at least a part of the problems described above, and can be realized as the following forms or application examples.

Application Example 1 A resin molding apparatus according to this application example plasticizes a stage, a storage tank installed on the stage, an energy beam irradiation unit that irradiates energy rays, and a first material that is a synthetic resin. , An injection unit that injects from the injection port, the stage, and the driving means that enables the energy beam irradiation unit and the injection unit to relatively move three-dimensionally, and the storage tank is at least in the direction of gravity A liquid curable resin material containing an energy beam curable resin that is cured by the energy beam is stored.

According to the resin molding apparatus of this application example, an energy beam irradiation unit that cures an energy beam curable resin that is easy to perform three-dimensional modeling, so-called 3D modeling, by energy beam irradiation, an injection unit that can inject a synthetic resin, The mold that enables injection molding of synthetic resin can be formed by 3D modeling by irradiating the energy ray curable resin with energy rays and hardening, and mold design, mold production, mold assembly The lead time from mold manufacture to product injection molding can be set shorter than before. As a result, even when a resin material that is not applicable to the energy beam curable resin is used, an expensive metal mold is not created, so that resin molding can be performed in a short time and at a low cost.

Application Example 2 In the application example described above, the energy beam irradiated from the energy beam irradiation unit hardens the cured resin material to form a first molded product in a layered form, and is injected from the injection unit. The first material is cured, a second molded product is formed in layers, the first molded product is laminated in the direction of gravity, and the second molded product is laminated in the direction of gravity. And 2 molded bodies are formed.

According to the application example described above, it is possible to easily obtain the first molded body and the second molded body that are 3D-shaped.

Application Example 3 In the application example described above, the first molded body is formed with a cavity for forming the second molded body, and the second molded body has the first material directed toward the cavity. It is injected and filled.

According to the application example described above, the first material can be used as a molding die, and the first material can be injection-molded into the cavity formed in the first molding. The lead time from mold manufacturing for mold assembly to product injection molding can be set shorter than before. As a result, even when a resin material that is not applicable to the energy beam curable resin is used, an expensive metal mold is not created, so that resin molding can be performed in a short time and at a low cost.

Application Example 4 In the application example described above, the injection unit plasticizes the first injection part that plasticizes the first material and injects it from the injection port, and the second material that is a synthetic resin. And at least a second injection part that injects from the injection port.

According to the resin molding apparatus of this application example, it is possible to inject at least two types of thermoplastic resins, and an energy beam irradiating unit that cures an energy beam curable resin that is easy for three-dimensional modeling, so-called 3D modeling, by energy beam irradiation. A mold capable of injection molding at least two types of thermoplastic resins can be formed by 3D modeling by irradiating the energy beam curable resin with energy rays and curing the mold. The lead time from design, mold production and mold assembly to mold injection can be set shorter than before. As a result, even when a resin material that is not applicable to the energy beam curable resin is used, an expensive metal mold is not created, so that resin molding can be performed in a short time and at a low cost.

Application Example 5 In the application example described above, the energy beam irradiated from the energy beam irradiation unit hardens the cured resin material to form a first molded product in a layered form, and the first injection unit Either or both of the first material to be injected and the second material to be injected from the second injection portion are cured to form a second molded product in a layer shape, and the first molding A first molded body in which an object is stacked in the direction of gravity and a second molded body in which the second molded object is stacked in the direction of gravity are formed.

According to the application example described above, it is possible to obtain a first molded body that is 3D-modeled easily and a second molded body that is 3D-modeled using two types of materials.

Application Example 6 In the application example described above, a cavity for forming the second molded body is formed in the first molded body, and the second molded body includes the first material and the second material. At least one or both of the materials are injected into the cavity and filled.

According to the application example described above, the first molded body is used as a molding die, and at least two kinds of materials, ie, the first material and the second material, are injection molded in the cavity formed in the first molded body. It is possible to set the lead time from mold manufacturing, mold manufacturing and mold assembly to injection molding of products shorter than before. As a result, even when a resin material that is not applicable to the energy beam curable resin is used, an expensive metal mold is not created, so that resin molding can be performed in a short time and at a low cost.

Application Example 7 In the application example described above, an insertion member supply unit that supplies an insertion member formed of a material different from the first material to the second molded product is provided, and the insertion member includes the second member. It is formed integrally with the molded body.

According to the application example described above, it is possible to obtain a second molded body in which an insertion member is included inside a 3D model.

Application Example 8 In the application example described above, the synthetic resin is a thermoplastic resin, and the insertion member is a metal.

According to the application example described above, precise molding by injection molding becomes possible by using a thermoplastic resin. Furthermore, since the insertion member is a metal, a molded body having a higher strength can be obtained as compared with a molded body formed only from synthetic resin. Moreover, even if the synthetic resin is a nonconductor, a conductive path can be formed in the molded body because the inserted member to be inserted is a conductive metal.

Application Example 9 In the application example described above, the energy beam is ultraviolet light.

According to the above-mentioned application example, since it is a low calorific energy ray with a high productivity due to a short curing time and a small calorific value of the irradiation part and ultraviolet rays, the thermal influence on the second material constituting the second molded product. Can be avoided.

Application Example 10 In the application example described above, the synthetic resin is a thermoplastic resin.

According to the application example described above, precise modeling by injection molding becomes possible.

Application Example 11 In the resin molding method of this application example, the energy beam curable resin is irradiated with an energy beam to a liquid curable resin material containing an energy beam curable resin stored in a storage tank installed on a stage. A mold-molded product single layer forming step in which a single-layer mold product single layer is cured, and a molding region formed in the mold-molded single layer by the first material which is a plasticized synthetic resin Injecting and filling from the injection part toward the single layer injection molding process to form a molded product single layer, and laminating the first molded product single layer formed by the mold molded product single layer forming step, A mold molded product laminating step for forming a second molded product monolayer by the mold molded product monolayer forming step, and a first molded product monolayer formed by the single layer injection molding step are laminated to form the single molded product. Molding to form a second molded product single layer by layer injection molding process A mold forming body in which the mold molding single layer is laminated a predetermined number of times, and the molding lamination process is performed the predetermined number of times. And repeatedly forming a molded body laminated on the molding region of the mold molded body.

According to the resin molding method of this application example, the thermoplastic resin is injected and laminated on the molded body obtained by curing and laminating the energy ray curable resin that is easy to 3D modeling by energy ray irradiation. Thus, a molded body can be obtained, and the lead time from mold manufacturing, mold manufacturing and mold assembly to mold injection molding can be set shorter than before. Therefore, even when a resin material that cannot be applied to the energy beam curable resin is used, an expensive metal mold is not created, and therefore, resin molding can be performed in a short time and at a low cost.

Application Example 12 In the application example 11 described above, in the single-layer injection molding step, the first material is injected from the first injection portion to form a cavity of the mold-molded single layer. A first single-layer injection molding step of filling and solidifying the cavity region to form a single layer of a molded product, and a second material that is a plasticized synthetic resin is injected from the second injection portion, And a second single-layer injection molding step of forming a single molded article layer by filling the second cavity region constituting the cavity of the single molded article mold and solidifying it.

According to the resin molding method of this application example, at least two types of thermoplastic resins are applied to a molded product obtained by curing and laminating an energy beam curable resin that is easy to 3D modeling by energy beam irradiation. A molded body can be obtained by injecting and laminating, and the lead time from mold production in mold design, mold production and mold assembly to product injection molding can be set shorter than before. Therefore, even when a resin material that cannot be applied to the energy beam curable resin is used, an expensive metal mold is not created, and therefore, resin molding can be performed in a short time and at a low cost.

Application Example 13 In the application example 12 described above, in the mold product single layer forming step, the cured resin material is cured at a boundary between the first cavity region and the second cavity region. And a boundary wall layer forming step for forming a boundary wall formed by the step.

According to the application example described above, the boundary between the first cavity region and the second cavity region can be determined by forming the boundary wall. Therefore, the material injected into the first cavity region and the material injected into the second cavity region are accurately injection-molded into the first cavity region and the second cavity region.

[Application Example 14] In the above application example 11, the molded product laminating step includes an insertion member supplying step in which the insertion member is arranged in the single molded product layer, and the insertion member is integrally formed with the molded body. It is characterized by that.

According to the application example described above, it is possible to obtain a molded body in which an insertion member is included inside a 3D model.

Application Example 15 In the application example 11 described above, the method includes a mold release step of releasing the molded body from the mold molded body, and the mold release step dissolves the mold molded body.

According to the application example described above, the molded product can be released from the molded product without damaging the molded product.

Application Example 16 In the above application example 11, the energy ray is ultraviolet light.

According to the above-described application example, since it is a low productivity energy beam with a low curing time and a high productivity due to a short curing time, it is possible to avoid a thermal influence on the molded body.

Application Example 17 In the above application example 11, the synthetic resin is a thermoplastic resin.

According to the application example described above, precise molding by injection molding becomes possible by using a thermoplastic resin.

Application Example 18 In the application example 14 described above, the insertion member is a metal.

According to the application example described above, a molded body having high strength can be obtained as compared with a molded body formed only of synthetic resin because the insertion member is a metal. Moreover, even if the synthetic resin is a nonconductor, a conductive path can be formed in the molded body because the inserted member to be inserted is a conductive metal.

The block diagram which shows schematic structure of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 1st Embodiment. The flowchart of the resin molding method which concerns on 2nd Embodiment. The external appearance perspective view which shows the 2nd molded object illustrated in the resin molding method which concerns on 2nd Embodiment. The detailed flowchart of the molded object single layer molding process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The detailed flowchart of the single layer injection molding process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The A section enlarged view shown in FIG. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 2nd Embodiment. The block diagram which shows schematic structure of the resin molding apparatus which concerns on 3rd Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 3rd Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 3rd Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 3rd Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 3rd Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 3rd Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 3rd Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 3rd Embodiment. The flowchart of the resin molding method which concerns on 4th Embodiment. The external appearance perspective view which shows the 2nd molded object illustrated in the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The detailed flowchart of the single layer injection molding process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 4th Embodiment. The block diagram which shows schematic structure of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The figure explaining the drive of the resin molding apparatus which concerns on 5th Embodiment. The flowchart of the resin molding method which concerns on 6th Embodiment. The external appearance perspective view which shows the 2nd molded object illustrated in the resin molding method which concerns on 6th Embodiment. The detailed flowchart of the molded object single layer formation process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The detailed flowchart of the single layer injection molding process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The B1 section enlarged view shown in FIG. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The B2 part enlarged view shown in FIG. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The B3 section enlarged view shown in FIG. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 6th Embodiment. The external appearance perspective view which shows the 2nd molded object illustrated in the resin molding method which concerns on 7th Embodiment. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 7th Embodiment. The D section enlarged view shown in FIG. The schematic sectional drawing which shows the manufacturing process of the resin molding method which concerns on 7th Embodiment.

Embodiments according to the present invention will be described below with reference to the drawings. In the following embodiments, the same components are denoted by the same reference numerals, and the description thereof may be omitted or simplified.

(First embodiment)
FIG. 1 is a configuration diagram showing a schematic configuration of a resin molding apparatus according to the first embodiment. A resin molding apparatus 1000 shown in FIG. 1 stores a stage 200 and a liquid resin material Mf as a liquid cured resin material including an energy ray curable resin that is installed on the stage 200 and is cured by being irradiated with energy rays. The storage tank 300 in which the storage space 300a is formed and the base 100 including a stage driving device (not shown) that drives the stage 200 three-dimensionally are provided. In the three-dimensional drive, the stage 200 can be driven in any of the X, Y, and Z directions shown in the figure.

In the storage space 300a of the storage tank 300, a molding unit 400 including a table 410 having a molded product formation surface 410a (hereinafter referred to as a formation surface 410a) and a drive shaft 420 that drives the table 410 in the Z-axis direction. Has been placed.

As described above, in the resin molding apparatus 1000, the storage tank 300 stores the liquid resin material Mf containing the energy beam curable resin as the cured resin material and is cured on the formation surface 410a by the energy beam as described later. Since the cured layer is formed and laminated, the liquid upper surface of the liquid resin material Mf and the formation surface 410a are arranged substantially in parallel. Therefore, it can be said that the Z-axis direction shown in the drawing is a so-called gravity direction, and the table 410 is driven in the gravity direction.

An energy ray irradiating unit 500 that irradiates energy rays toward the liquid upper surface of the liquid resin material Mf is disposed at the upper part in the gravity direction of the storage tank 300. Note that the resin molding apparatus 1000 according to the present embodiment will be described by exemplifying ultraviolet rays as energy rays. Therefore, the energy beam irradiation unit 500 will be described as the ultraviolet irradiation unit 500 below.
The energy beam for curing the energy beam curable resin is not limited to ultraviolet rays, and may be high frequency, radiation, or other energy beam that imparts energy for curing the irradiated object.

In addition, an injection unit 600 that plasticizes and injects a resin material Mp as a first material, which is a synthetic resin, which is a product material, is arranged at the upper part in the gravity direction of the storage tank 300. In this embodiment, an injection unit 600 including a flat screw will be described as an example.

The injection unit 600 includes a heater (heating means) (not shown), and has a cylinder 620 having an internal space, a flat screw 630 disposed in the internal space of the cylinder 620, and a driving device 640 that rotationally drives at least the flat screw 630. , And a material supply unit 610 that supplies the pellet-shaped resin material Mp to the internal space of the cylinder 620.

The pellet-shaped resin material Mp supplied to the cylinder 620 is heated to a temperature equal to or higher than the glass transition point by a heater provided in the cylinder 620 to become a plasticized resin material Mp. The plasticized resin material Mp is sent to the injection port 620b by rotating the flat screw 630, and is injected from the injection port 620b.

The injection principle of the resin material Mp by the flat screw 630 is that the pellet-shaped resin material Mp is conveyed from the material supply unit 610 to the material input port 620a of the cylinder 620 and plasticized by the heater of the cylinder 620. The plasticized resin material Mp is formed in a spiral shape from the outside of the flat screw 630 toward the rotation center 630r when the flat screw 630 is rotated around the rotation center 630r by the driving device 640. The plasticized resin material Mp is conveyed under pressure toward the rotation center 630r along the conveyance groove 630a, and is injected from the injection port 620b by the pressure.

The resin molding apparatus 1000 according to this embodiment includes a control unit 700, a stage controller 710 that controls driving of a stage driving device (not shown) provided in the base 100, and molding that is driven in the direction of gravity in the storage tank 300. A table controller 720 that controls a table driving device (not shown) that drives the unit 400, an ultraviolet irradiation control unit 730 that controls the ultraviolet irradiation unit 500, and an injection control unit 740 that controls the injection unit 600 are controlled.

2 to 5 are diagrams for explaining the driving of the resin molding apparatus 1000. FIG. FIG. 2 is a schematic configuration diagram showing a preparation stage for resin molding by the resin molding apparatus 1000. As shown in FIG. 2, in the resin molding preparation stage of the resin molding apparatus 1000, the liquid resin material Mf in which a cured product is generated by irradiating the storage space 300 a of the storage tank 300 with ultraviolet rays UV as energy rays is generated. Store.

Then, the formation surface 410a of the table 410 is submerged in a depth D _L1 from the liquid surface Sf of the stored liquid resin material Mf. The depth D _L1 is the amount of sinking of the table 410 required to obtain the thickness of the first layer of the molded product to be described later.

In the injection unit 600, the pellet-shaped resin material Mp is charged from the hopper 610 a of the material supply unit 610 and conveyed to the cylinder 620. In the cylinder 620, the resin material Mp is heated to a temperature exceeding the glass transition point by a heater (not shown) and plasticized. The resin material Mp plasticized by the rotation of the flat screw 630 is pressurized and conveyed to the injection port 620b.

When preparation for resin molding of the resin molding apparatus 1000 shown in FIG. 2 is completed, ultraviolet rays UV as energy rays are emitted from the ultraviolet irradiation port of the ultraviolet irradiation unit 500 toward the liquid surface Sf of the liquid resin material Mf as shown in FIG. Is irradiated. The stage 200 is driven in the XY direction relative to the ultraviolet irradiation unit 500 by a stage driving device (not shown) provided in the base 100 in synchronization with the irradiation of the ultraviolet UV, and is stored on the stage 200. The tank 300 is moved relative to the ultraviolet irradiation unit 500 in the XY direction. The liquid resin material Mf is cured by being irradiated with ultraviolet rays UV, and a first molding die layer 801 as a first molded first layer having a thickness of D _L1 is formed on the formation surface 410a. The

Next, the resin material Mp plasticized from the injection port 620b of the injection part 600 is injected into the molding region 801s surrounded by the first mold layer 801 described in FIG. 3 as shown in FIG. A first molded layer 901 as a second molded product of the layer is formed on the forming surface 410a. In this example, the form in which the first molding layer 901 is formed is illustrated with the inside of the first molding die layer 801 formed in a frame shape as the first molding region 801s.

As described above, the liquid resin material Mf is cured by ultraviolet UV to form the first mold layer 801, and the resin material Mp plasticized using the first mold layer 801 as a mold frame is injected from the injection unit 600. By forming the first molded layer 901, a layered molded product is formed. Then, by repeating the formation of the layered molded product, the molded product is formed on the forming surface 410a of the table 410 as shown in FIG.

FIG. 5 shows a state in which the formation of the layered molding described above is repeated and laminated. As shown in FIG. 5, a second second mold layer 802 is laminated on the first first mold layer 801. In this embodiment, a cup-like shape with the first molded layer 901 of the second molded body 900 described later as the bottom is illustrated. In the second mold layer 802 of the second layer, the second mold outer mold layer 802a is laminated on the upper surface of the first mold layer 801 so as to constitute a second mold region 802s that forms the second mold layer 902. Then, the second molded inner mold layer 802b is laminated on the upper surface of the first molded layer 901. Then, the resin material Mp is injected into the second layer molding region 802 s to form the second molding layer 902.

Next, a third molded outer mold layer 803a is laminated on the upper surface of the second molded outer mold layer 802a so as to form a third molded region 803s forming the third molded layer 903, and the third molded inner mold layer is formed. 803b is laminated on the upper surface of the second molding inner mold layer 802b to form a third molding mold layer 803 as the third layer. Then, the resin material Mp is injected into the third-layer molding region 803 s to form the third molding layer 903.

Further, the N-th N-th mold layer 80N and the N-th mold layer 90N are sequentially stacked on the third-layer third mold layer 803 and the third mold layer 903, and the first molded body 800, The second molding 900 is formed by filling a molding region formed by the one molding 800, that is, a so-called cavity, with the resin material Mp.

As described above, the first molded body 800 is a molding resin mold in which a cavity that is a space for molding the second molded body 900 is formed. Therefore, it is not necessary to prepare an expensive metal mold for manufacturing the second molded body 900 as a product, that is, a so-called mold, and the liquid resin material Mf is easily cured by ultraviolet rays UV as energy rays. Solid modeling, so-called 3D modeling, is possible. Further, the second molded body 900 as a product can be formed by so-called injection molding in which a resin material Mp of a thermoplastic resin is injected from the injection part 600 and the first molded body 800 is molded as a molding die. Therefore, the resin material Mp may be a thermoplastic resin. This is because, conventionally, in a modeling apparatus that generally performs 3D modeling using an ultraviolet curable resin, the resin material of the product is limited to the ultraviolet curable resin. In other words, if a resin that cannot be cured by ultraviolet rays is designated as the product resin, it is necessary to rely on injection molding using a mold.

According to the resin molding apparatus 1000 according to the present embodiment, a mold for injection molding of a thermoplastic resin can be molded with an energy ray curable resin capable of 3D modeling at a low cost in a short time. Therefore, even when a resin material that cannot be applied to the energy beam curable resin is used, an expensive metal mold is not created, and therefore, resin molding can be performed in a short time and at a low cost.

(Second Embodiment)
As a second embodiment, a resin molding method using the resin molding apparatus 1000 according to the first embodiment will be described. FIG. 6 is a flowchart of the resin molding method according to the second embodiment. In the flowchart shown in FIG. 6, a predetermined amount of the liquid resin material Mf is stored in a storage tank 300 provided in the resin molding apparatus 1000 in advance as preparation for manufacturing, and the pellet-shaped resin material Mp is stored in the material supply unit 610 of the injection unit 600. Supply. Then, the resin material Mp heated and plasticized by a heater (not shown) provided in the cylinder 620 is advanced to a state where it is conveyed to the injection port 620b. This manufacturing preparation is completed, and the flowchart shown in FIG. 6 is started.

In the description of the resin molding method according to the second embodiment, a method of molding the second molded body 900 described in the first embodiment will be described by taking the form shown in the external perspective view of FIG. 7 as an example. Hereinafter, the second molded body 900 is referred to as a molded body 900. As illustrated in FIG. 7, the molded body 900 has a frustoconical outer shape having a cross-sectional shape 900 a, and illustrates a container including an internal space and a bottom.

(Molded product single layer forming process)
First, a molded product single layer forming step (S1) is performed. A detailed flowchart of the molded product single layer forming step (S1) is shown in FIG.

(The stage / table is driven to the molding start position)
The storage tank 300 in which the liquid resin material Mf is stored in the preparation step described above and the table 410 provided in the storage tank 300 are driven by the stage driving device provided in the base 100, and the table is driven to the molding start position ( Step S11) is executed. In the step of driving the table to the molding start position (S11), as shown in FIG. 9, the interval Duv between the forming surface 410a of the table 410 and the ultraviolet emitting unit 500a of the ultraviolet irradiating unit 500 is set to a predetermined interval. The relative position between the table 410 and the ultraviolet irradiation unit 500 is set. The predetermined interval of the interval Duv is a distance that the ultraviolet ray UV irradiated from the ultraviolet irradiation unit 500 can reach as the energy that can cure the liquid resin material Mf just above the formation surface 410a. Then, the table 410 and the storage tank 300 are moved such that the relative position between the table 410 and the storage tank 300 is a position where the formation surface 410a is at the depth D _L1 from the liquid surface Sf of the liquid resin material Mf. The depth D _L1 is the molding thickness of the first layer to be molded first, which will be described later.

(UV irradiation process)
When the ultraviolet irradiation unit 500 is disposed at a predetermined relative position with respect to the table 410, an ultraviolet irradiation step (S12) is executed. In the ultraviolet irradiation step (S12), the ultraviolet irradiation unit 500 moves relative to the table 410 while irradiating the ultraviolet ray UV from the ultraviolet irradiation unit 500 while maintaining the depth D _L1 as shown in FIG. The stage 200 is driven. By moving the ultraviolet irradiation unit 500 relative to the outer shape of the molded body 900 shown in FIG. 7 while irradiating ultraviolet rays UV, the first layer forming region 801s is formed on the inner side. A first mold layer 801 as a single mold layer is formed.
When the first molding die layer 801 of the first layer is formed, the ultraviolet irradiation step (S12) in the molded product single layer forming step (S1) is completed, and then the single layer injection molding step (S2) is performed. Migrated.

(Single layer injection molding process)
In the single-layer injection molding step (S2), the first molding die layer 801 as the first molding single layer formed by the ultraviolet irradiation step (S12) on the forming surface 410a of the table 410 is used as a mold frame. A single layer as a part of the molded body 900 is injection molded. FIG. 11 shows a detailed flowchart of the single-layer injection molding step (S2).

(Driving the table to the injection molding start position)
In the single-layer injection molding step (S2), first, as shown in FIG. 12, the table 200 is driven so that the injection port 620b of the injection unit 600 is disposed at the injection molding start position as a relative position with respect to the table 410. Is driven to the injection molding start position (S21). At this time, the stage 200 is driven without changing the depth D _L1 of the formation surface 410a of the table 410 from the liquid surface Sf of the liquid resin material Mf.

(Injection molding process)
When the step of driving the table to the injection molding start position (S21) is executed, the table is transported to the injection port 620b of the injection unit 600 in the preparation process, and heated to the glass transition point or more by the heater provided in the injection unit 600 to be plasticized. As shown in FIG. 13, the resin material Mp thus injected is injected from the injection port 620 b toward the table 410 with a predetermined pressure. At this time, the resin material Mp is injected and filled into a molding region 801 s which is a cavity formed inside the first molding die layer 801 formed in the mold molding single layer forming step (S 1).

The state of injection of the resin material Mp from the injection port 620b of the injection unit 600 shown in FIG. 13 will be described with reference to FIG. For convenience of explanation in FIG. 14, the plasticized resin material Mp is referred to as a plastic resin Mpf, and the resin material Mp solidified from the plasticized state is referred to as a solidified resin Mps.

As shown in FIG. 14, the plastic resin Mpf is pressurized by the rotation drive of the flat screw 630 and is injected from the injection port 620b. The injected plastic resin Mpf is cooled to a temperature lower than the glass transition point in the process of reaching the formation surface 410a of the table 410, so that the form changes to the solidified resin Mps. The plastic resin Mpf is continuously laminated and solidified on the solidified resin Mps, and the solidified resin Mps is formed as a molded product in the molding region 801s of the first mold layer 801.

At this time, since the uncured liquid resin material Mf remains inside the first mold layer 801 formed in a frame shape, the plastic resin Mpf touches the remaining liquid resin material Mf. It is possible to promote solidification by cooling to become the solidified resin Mps. Accordingly, it is possible to shorten the time of the plastic resin Mpf state on the forming surface 410a, to prevent unnecessary flow in the XY direction shown in the figure, so-called outflow, and to perform molding with an accurate shape. it can.

As described above, the injection unit 600 included in the resin molding apparatus 1000 according to the first embodiment used in the resin molding method according to the present embodiment applies a pressure from the injection port 620b and injects the plastic resin Mpf. This is an embodiment of a so-called injection molding method.

Then, as shown in FIG. 15, while injecting the plasticized resin material Mp from the injection port 620b, the stage 200 is driven so that the injection unit 600 moves along a predetermined path relative to the table 410, and the first The resin material Mp is disposed in a molding region 801s constituted by the molding die layer 801, and a first molding layer 901 as a first molding single layer is formed. In the present embodiment, since the formation of the molded body 900 shown in FIG. 7 is illustrated, the first molded layer 901 corresponds to the bottom of the molded body 900 and is formed in a flat plate shape.

When the first molding layer 901 of the first layer is formed, the injection molding process (S22) in the single-layer injection molding process (S2) is completed, and then the process proceeds to the stacking number confirmation process (S3).

(Stacking number confirmation process)
In the resin molding method according to the present embodiment, the first molded mold layer 801 and the single layer of the first molded layer 901 are stacked up to N layers (N: a natural number of 1 or more) to form the molded body 900. . Therefore, the uppermost molded product single layer formed in the single layer injection molding step (S2) immediately before the number of laminated product confirmation step (S3) is confirmed, and the molded product single layer is laminated up to a predetermined number of laminated layers (N layers). A stacking number confirmation step (S3) for determining whether or not it has been performed is executed.

When it is determined in the number-of-stacks confirmation step (S3) that the molded product single layer formed in the immediately preceding single-layer injection molding step (S2) has not been formed to a predetermined number of layers (N layers), in other words, the number of layers When it is determined that the number is smaller than N (NO), the process proceeds to the stacking step (S4).

(Lamination process)
The laminating step (S4) in the resin molding method according to the present embodiment is a command step for repeatedly executing the molded product single layer forming step (S1) and the single layer injection molding step (S2). Mold molding lamination step (S41) instructing repetition of the molding single layer formation step (S1) for newly forming a molding single layer on the uppermost mold molding single layer confirmed in the step (S3) ) And a molding laminate process (S2) for instructing repetition of a single-layer injection molding process (S2) for newly forming a molding monolayer on the uppermost molding monolayer confirmed in the lamination number confirmation process (S3) ( S42). In accordance with the command issued in the mold molding lamination step (S41) included in the lamination step (S4), a new mold molding single layer is molded on the uppermost mold molding single layer already formed on the table 410. The process proceeds to the molded product single layer forming step (S1).

In the mold product single layer forming step (S1) executed based on the command of the mold product stacking step (S41) included in the stacking step (S4), first, the step of driving the table to the molding start position (S11) is executed. Is done. As shown in FIG. 16, in the step of driving the table to the molding start position (S11), the upper surface of the first mold layer 801 as the first mold molded product single layer formed on the table 410, and the ultraviolet irradiation unit The relative positions of the table 410 and the ultraviolet irradiation unit 500 are set so that the 500 ultraviolet emitting units 500a have a distance Duv.
The interval Duv in the step of driving the table related to the stacking step (S4) to the molding start position (S11) is the liquid resin material Mf directly above the first mold layer 801 by the ultraviolet UV irradiated from the ultraviolet irradiation unit 500. Is the distance that can be reached as energy that can be cured. Then, the table 410 and the storage tank 300 are positioned relative to each other so that the upper surface of the first mold layer 801 is at a depth D _L2 from the liquid surface Sf of the liquid resin material Mf. Move. The depth D _L2 is the molding thickness of the second layer of the molded product single layer.

Next, the process proceeds to the ultraviolet irradiation step (S12). In the ultraviolet irradiation process (S12) according to the molded product lamination step (S41) included in the lamination step (S4), the ultraviolet ray UV irradiation unit 500 irradiates ultraviolet rays UV while maintaining the depth D _L2 as shown in FIG. The stage 200 is driven so that the ultraviolet irradiation unit 500 moves relative to the table 410 and follows the shape of the molded body 900. And the 2nd shaping | molding die layer 802 as a 2nd 2nd shaping | molding molding single layer is formed by the ultraviolet irradiation part 500 moving relatively, irradiating ultraviolet-ray UV. The second molding die layer 802 includes a second molding outer mold layer 802a for forming the outer shape of the molded body 900 and a second molding inner mold layer 802b for forming the inner side of the molded body 900. The The second molding outer mold layer 802a is laminated on the first first molding mold layer 801, but the molded body 900 exemplified in the present embodiment is formed by the first molding layer 901 serving as a flat bottom. Therefore, the second molded inner mold layer 802b is laminated on the first molded layer 901. And the 2nd molding area | region 802s enclosed by the 2nd shaping | molding outer mold layer 802a and the 2nd shaping | molding inner mold layer 802b is comprised.

Subsequently, a single layer injection molding step (S2) related to the molded product laminating step (S42) included in the laminating step (S4) is performed, and the second layer is formed on the first molded layer 901 as the first molded single layer. The second molded product single layer is formed. As shown in FIG. 18, the single-layer injection molding step (S2) related to the stacking step (S4) is the second molding die layer 802 formed by the mold single layer forming step (S1) related to the stacking step (S4). The resin material Mp plasticized from the injection port 620b is injected into the molding region 802s while the injection port 620b of the injection unit 600 is moved relative to the table 410 so as to face the molding region 802s. And the 2nd molding layer 902 as a 2nd 2nd molding single layer which comprises the molded object 900 with the injected resin material Mp is formed.

When the second molding layer 902 is formed by the single-layer injection molding step (S2) related to the molding lamination step (S42) included in the lamination step (S4), the process proceeds to the lamination number confirmation step (S3), and the number of laminations is confirmed. It is determined whether or not the molded product single layer formed in the single layer injection molding step (S2) immediately before the step (S3) has been laminated up to a predetermined number of layers (N layers). And when it determines with the number of lamination | stacking of the molding single layer formed by the immediately preceding single layer injection molding process (S2) being smaller than N (NO), it transfers to a lamination process (S4) again.

In the above-described laminating step (S4), the first mold single layer, the second mold single layer, the first mold single layer, and the first single mold second layer, The second means simply the order, not the number of layers. For example, when the fourth mold layer 804 as the fourth layer is laminated on the third mold layer 803 as the third layer, the third mold layer 803 is referred to as a first mold product single layer, and the fourth mold is formed. The mold layer 804 is referred to as a second mold product single layer. Similarly, when the fourth molded layer 904 of the fourth layer is laminated on the third molded layer 903 of the third layer, the third molded layer 903 is called a first molded product single layer, and the fourth molded layer 904 is This is called the second molded product single layer.

As shown in FIG. 19, the lamination step (S4) is repeated a predetermined number of times, and as shown in FIG. 19, as a molded body in which N layers from the first molding die layer 801 to the N-th molding die layer 80N are laminated. Using the first molded body 800 and the first molded body 800 as a molding die, a resin material Mp is injected into a so-called cavity in the molding regions 801s, 802s, 803s,. To a N-th molded layer 90N, a molded body 900 is formed as a second molded body in which N layers are stacked.
And it transfers to the lamination | stacking number confirmation process (S3), and it determines with the molded object single layer formed by the last single layer injection molding process (S2) having been formed to the predetermined number of lamination | stacking (N layers) (YES). If so, the process proceeds to a release step (S5).

(Release process)
The mold release step (S5) is a step of separating the molded body 900 from the first molded body 800 and taking out the molded body 900. As the release step (S5), release by physical means or release by chemical means is used. As a physical mold release means, the first molded body 800 is broken by applying an impact to the first molded body 800 with a hammer or the like, and high pressure air is pressed into the boundary between the first molded body 800 and the molded body 900. Means such as separating 800 and molded body 900 can be applied.

As the chemical release means, it is preferable to apply a release means for separating the molded body 900 by immersing the ultraviolet curable resin constituting the first molded body 800 in a solvent that selectively dissolves. Thereby, there is no possibility of damaging the molded object 900, and it can mold-separate from the 1st molded object 800.

The resin molding method according to the second embodiment by the resin molding apparatus 1000 according to the first embodiment is a known three-dimensional resin molding in which an injection molding die for obtaining a molded body 900 uses a resin that is cured by energy rays. It is formed as a resin mold by the method. As a result, it is possible to achieve a significant reduction in mold production time and a reduction in equipment costs by eliminating the need for a metal processing apparatus for mold production.

(Third embodiment)
FIG. 20 is a configuration diagram showing a schematic configuration of a resin molding apparatus according to the third embodiment. A resin molding apparatus 1000A shown in FIG. 20 stores a stage 200 and a liquid resin material Mf as a liquid cured resin material that is installed on the stage 200 and includes an energy ray curable resin that is cured by being irradiated with energy rays. The storage tank 300 in which the storage space 300a is formed and the base 100 including a stage driving device (not shown) that drives the stage 200 three-dimensionally are provided. The three-dimensional drive is capable of driving in any of the X, Y, and Z directions shown in the figure.

In the storage space 300a of the storage tank 300, a molding unit 400 including a table 410 having a molded product formation surface 410a (hereinafter referred to as a formation surface 410a) and a drive shaft 420 that drives the table 410 in the Z-axis direction. Has been placed.

As described above, in the resin molding apparatus 1000A, the storage tank 300 stores the liquid resin material Mf containing the energy beam curable resin as the cured resin material, and is cured on the formation surface 410a by the energy beam as described later. Since the cured layer is formed and laminated, the liquid upper surface of the liquid resin material Mf and the formation surface 410a are arranged substantially in parallel. Therefore, it can be said that the Z-axis direction shown in the drawing is a so-called gravity direction, and the table 410 is driven in the gravity direction.

In the upper part of the storage tank 300 in the gravity direction, an energy beam irradiation unit 500 that irradiates energy beams toward the liquid surface of the liquid resin material Mf is disposed. In the resin molding apparatus 1000A according to the present embodiment, ultraviolet rays will be exemplified and described as energy rays. Therefore, the energy beam irradiation unit 500 will be described as the ultraviolet irradiation unit 500 below. The energy beam for curing the energy beam curable resin is not limited to ultraviolet rays, and may be high frequency, radiation, or other energy beam that imparts energy for curing the irradiated object.

In addition, an injection unit 600 that plasticizes and injects a resin material Mp as a first material, which is a synthetic resin, which is a product material, is arranged at the upper part in the gravity direction of the storage tank 300. In this embodiment, an injection unit 600 including a flat screw will be described as an example.

The injection unit 600 includes a heater (heating means) (not shown), and has a cylinder 620 having an internal space, a flat screw 630 disposed in the internal space of the cylinder 620, and a driving device 640 that rotationally drives at least the flat screw 630. , And a material supply unit 610 that supplies the pellet-shaped resin material Mp to the internal space of the cylinder 620.

The pellet-shaped resin material Mp supplied to the cylinder 620 is heated to a temperature equal to or higher than the glass transition point by a heater provided in the cylinder 620 to become a plasticized resin material Mp. The plasticized resin material Mp is sent to the injection port 620b by rotating the flat screw 630, and is injected from the injection port 620b.

The injection principle of the resin material Mp by the flat screw 630 is that the pellet-shaped resin material Mp is conveyed from the material supply unit 610 to the material input port 620a of the cylinder 620 and plasticized by the heater of the cylinder 620. The plasticized resin material Mp is formed in a spiral shape from the outside of the flat screw 630 toward the rotation center 630r when the flat screw 630 is rotated around the rotation center 630r by the driving device 640. The plasticized resin material Mp is conveyed under pressure toward the rotation center 630r along the conveyance groove 630a, and is injected from the injection port 620b by the pressure.

The resin molding apparatus 1000A according to the present embodiment includes a robot 2000 as an insertion member supply unit. The robot 2000 includes an arm part 2000b composed of a plurality of arms and joints from a base part 2000a fixed to an apparatus base (not shown), and a hand part 2000c attached to the tip of the arm part 2000b. For convenience of explanation, the robot 2000 is depicted in an external perspective view in FIG.

The robot 2000 grips the insertion member Ti stored in the member tray 2100 by the hand unit 2000c, and conveys and supplies the inserted member Ti to a predetermined position. In this example, as will be described later, the insertion member Ti is supplied to the molded body formed in the molded portion 400. In this example, the robot 2000 is a so-called articulated robot, but the present invention is not limited to this. The insertion member Ti can be transported manually by an operator (person) in place of the robot 2000, but it is preferable to apply the robot 2000 as an apparatus from the viewpoint of safety and accuracy.

The insertion member Ti is a material different from at least the resin material Mp. For example, it is a preformed thermoplastic resin member or metal. The insertion member Ti can determine the material and shape of the insertion member Ti depending on the purpose, such as improving the strength of the molded body or imparting conductivity to the molded body by using a conductor. In this example, a stainless steel having excellent corrosion resistance will be described as an example.

The resin molding apparatus 1000A according to the present embodiment includes a control unit 700A, a stage controller 710 that controls driving of a stage driving device (not shown) provided in the base 100, and molding that is driven in the gravity direction in the storage tank 300. A table controller 720 that controls a table driving device (not shown) that drives the unit 400, an ultraviolet irradiation control unit 730 that controls the ultraviolet irradiation unit 500, an injection control unit 740 that controls the injection unit 600, and a drive of the robot 2000. Controlling the robot controller 750.

21 to 27 are diagrams for explaining the driving of the resin molding apparatus 1000A. FIG. 21 is a schematic configuration diagram showing a preparation stage of resin molding by the resin molding apparatus 1000A. As shown in FIG. 21, in the resin molding preparation stage of the resin molding apparatus 1000A, the liquid resin material Mf in which a cured product is generated by irradiating the storage space 300a of the storage tank 300 with ultraviolet rays UV as energy rays is generated. Store.

Then, the formation surface 410a of the table 410 is submerged in a depth D _L1 from the liquid surface Sf of the stored liquid resin material Mf. The depth D _L1 is the amount of sinking of the table 410 required to obtain the thickness of the first layer of the molded product to be described later.

In the injection unit 600, the pellet-shaped resin material Mp is charged from the hopper 610 a of the material supply unit 610 and conveyed to the cylinder 620. In the cylinder 620, the resin material Mp is heated to a temperature exceeding the glass transition point by a heater (not shown) and plasticized. The resin material Mp plasticized by the rotation of the flat screw 630 is pressurized and conveyed to the injection port 620b.

When the resin molding preparation of the resin molding apparatus 1000A shown in FIG. 21 is completed, the ultraviolet ray UV as an energy ray is emitted from the ultraviolet irradiation port of the ultraviolet irradiation unit 500 toward the liquid surface Sf of the liquid resin material Mf as shown in FIG. Is irradiated. The stage 200 is driven in the XY direction relative to the ultraviolet irradiation unit 500 by a stage driving device (not shown) provided in the base 100 in synchronization with the irradiation of the ultraviolet UV, and is stored in the stage 200. 300 is moved relative to the ultraviolet irradiation unit 500 in the XY direction. The liquid resin material Mf is cured by being irradiated with ultraviolet rays UV, and a first molding die layer 801 as a first molded first layer having a thickness of D _L1 is formed on the formation surface 410a. The

Next, the resin material Mp plasticized from the injection port 620b of the injection part 600 is injected into the molding region 801s surrounded by the first mold layer 801 described in FIG. 22 as shown in FIG. A first molded layer 901 as a second molded product of the layer is formed on the forming surface 410a. In this example, the form in which the first molding layer 901 is formed is illustrated with the inside of the first molding die layer 801 formed in a frame shape as the first molding region 801s.

When the first molding layer 901 shown in FIG. 23 is formed, the second layer is formed as shown in FIG. As shown in FIG. 24, the upper surfaces of the formed first mold layer 801 and the first molded layer 901 are submerged in a depth D _L2 from the liquid level Sf of the stored liquid resin material Mf. The formation surface 410a of the table 410 is lowered. The depth D _L2 is a sinking amount of the table 410 required to obtain the thickness of the second layer of the molded product to be described later.

Then, ultraviolet rays UV are irradiated from the ultraviolet irradiation unit 500 toward the liquid surface Sf of the liquid resin material Mf, and are driven relative to the ultraviolet irradiation unit 500 in the XY directions in synchronization with the irradiation of the ultraviolet rays UV. By the stage 200, the liquid resin material Mf is cured by being irradiated with the ultraviolet ray UV, and the second mold layer 802 as the first molded product of the second layer having the thickness of D _L2 is formed into the first mold. It is formed on the upper surface of the layer 801 and the first molding layer 901.

The second mold layer 802 is configured by forming a second mold outer mold layer 802a and a second mold inner mold layer 802b as shown in FIG. The second molding outer mold layer 802a and the second molding inner mold layer 802b form a second molding area 802s.

As shown in FIG. 25, the insertion member Ti is conveyed toward the formed region 802s. The insertion member Ti holds the insertion member Ti accommodated in the member tray 2100 shown in FIG. 20 by the hand unit 2000c of the robot 2000, and is conveyed to a predetermined position. In this example, it is placed on the first molding layer 901 in the molding region 802s.

The plastic material Mp plasticized from the injection port 620b of the injection part 600 is injected into the second layer molding region 802s on which the insertion member Ti described in FIG. 25 is placed as shown in FIG. A second molded layer 902 as a second molded product of the layer is formed on the first molded layer 901 of the first layer including the insertion member Ti inside.

As described above, the liquid resin material Mf is cured by ultraviolet UV to form the first mold layer 801, and the resin material Mp plasticized using the first mold layer 801 as a mold frame is injected from the injection unit 600. By forming the first molded layer 901, a layered molded product is formed. Subsequently, by forming the second molding layer 902 as the second layer using the second molding die layer 802 as a mold, including the insertion member Ti, and further laminating the formation of the layered molding, 27, a molded product is formed on the forming surface 410a of the table 410.

FIG. 27 shows a state in which the formation of the layered molding described above is repeated and laminated. As shown in FIG. 27, a second second mold layer 802 is laminated on the first first mold layer 801. In this embodiment, a cup-like shape with the bottom of the first molded layer 901 of the second molded body 900A described later is illustrated. Then, as shown in FIG. 26, the insertion member Ti is placed in the molding region 802s of the second second mold layer 802, and the resin material Mp is injected to form the second second molding layer 902. .

Subsequently, as shown in FIG. 27, a third molded outer mold layer 803a is laminated on the upper surface of the second molded outer mold layer 802a so as to constitute a third molding region 803s that forms the third molded layer 903, The third molding inner mold layer 803b is laminated on the upper surface of the second molding inner mold layer 802b to form the third third molding mold layer 803. Then, the resin material Mp is injected into the third-layer molding region 803 s to form the third molding layer 903.

Further, an N-th N-th mold layer 80N and an N-th mold layer 90N are sequentially stacked on the third-layer third mold layer 803 and the third mold layer 903, the first molded body 800A, A molding region formed by one molded body 800A, that is, a so-called cavity is filled with the resin material Mp to form a second molded body 900A. The second molded body 900A is formed so as to include the insertion member Ti in the resin material Mp. In this example, although the form containing two insertion members Ti is illustrated, it is not limited to this.

As described above, the first molded body 800A is a molding resin mold in which a cavity that is a space for molding the second molded body 900A is formed. Therefore, it is not necessary to prepare an expensive metal mold for manufacturing the second molded body 900A as a product, that is, a so-called mold, and the liquid resin material Mf is easily cured by ultraviolet rays UV as energy rays. Solid modeling, so-called 3D modeling, is possible. Further, the second molded body 900A as a product can be formed by so-called injection molding in which a thermoplastic resin material Mp is injected from the injection portion 600 and the first molded body 800A is molded as a molding die. Therefore, the resin material Mp may be a thermoplastic resin. This is because, conventionally, in a modeling apparatus that generally performs 3D modeling using an ultraviolet curable resin, the resin material of the product is limited to the ultraviolet curable resin. In other words, if a resin that cannot be cured by ultraviolet rays is designated as the product resin, it is necessary to rely on injection molding using a mold.

According to the resin molding apparatus 1000A according to the present embodiment, it is possible to mold a mold for injection molding of a thermoplastic resin with an energy ray curable resin capable of 3D modeling in a short time and at a low cost. Therefore, even when a resin material that cannot be applied to the energy beam curable resin is used, an expensive metal mold is not created, and therefore, resin molding can be performed in a short time and at a low cost.

Furthermore, the resin molding apparatus 1000A according to the present embodiment can be formed by integrally including an insertion member Ti such as metal inside the second molded body 900A. Therefore, the strength of the second molded body 900A can be reinforced by the insertion member Ti. Alternatively, even if the resin material Mp is a material that does not have conductivity, a conductive path can be formed in the second molded body 900A by using the insertion member Ti as a conductive material.

(Fourth embodiment)
As the fourth embodiment, a resin molding method using the resin molding apparatus 1000A according to the third embodiment will be described. FIG. 28 is a flowchart of a resin molding method according to the fourth embodiment. In the flowchart shown in FIG. 28, as a preparation for manufacturing, a predetermined amount of the liquid resin material Mf is stored in the storage tank 300 provided in the resin molding apparatus 1000A, and the pellet-shaped resin material Mp is stored in the material supply unit 610 of the injection unit 600. Supply. Then, the resin material Mp heated and plasticized by a heater (not shown) provided in the cylinder 620 is advanced to a state where it is conveyed to the injection port 620b. A predetermined number of insertion members Ti are accommodated in the member tray 2100. This manufacturing preparation is completed, and the flowchart shown in FIG. 28 is started.

In the description of the resin molding method according to the fourth embodiment, a method of molding the second molded body 900A described in the third embodiment will be described by taking the form shown in the external perspective view of FIG. 29 as an example. Hereinafter, the second molded body 900A is referred to as a molded body 900A. As shown in FIG. 29, the molded body 900A has a cylindrical outer shape having a cross-sectional shape 900Aa, and is a container including a cylindrical inner space and a bottom portion, and includes two insertion members Ti therein. ing. In this example, the insertion member Ti is made of an annular stainless steel having a rectangular cross section.

(Molded product single layer forming process)
First, a molded product single layer forming step (S1) is performed. Since the molded product single layer forming step (S1) is the same as that of the first embodiment, it will be described with reference to the detailed flowchart of FIG.

(The stage / table is driven to the molding start position)
The storage tank 300 in which the liquid resin material Mf is stored in the preparation step described above and the table 410 provided in the storage tank 300 are driven by the stage driving device provided in the base 100, and the table is driven to the molding start position ( Step S11) is executed. In the step of driving the table to the molding start position (S11), as shown in FIG. 9, the interval Duv between the forming surface 410a of the table 410 and the ultraviolet emitting unit 500a of the ultraviolet irradiating unit 500 is set to a predetermined interval. The relative position between the table 410 and the ultraviolet irradiation unit 500 is set. The predetermined interval of the interval Duv is a distance that the ultraviolet ray UV irradiated from the ultraviolet irradiation unit 500 can reach as the energy that can cure the liquid resin material Mf just above the formation surface 410a. Then, the table 410 and the storage tank 300 are moved such that the relative position between the table 410 and the storage tank 300 is a position where the formation surface 410a is at the depth D _L1 from the liquid surface Sf of the liquid resin material Mf. The depth D _L1 is the molding thickness of the first layer to be molded first, which will be described later.

(UV irradiation process)
When the ultraviolet irradiation unit 500 is disposed at a predetermined relative position with respect to the table 410, an ultraviolet irradiation step (S12) is executed. In the ultraviolet irradiation step (S12), the ultraviolet irradiation unit 500 moves relative to the table 410 while irradiating the ultraviolet ray UV from the ultraviolet irradiation unit 500 while maintaining the depth D _L1 as shown in FIG. The stage 200 is driven. The first layer mold in which the first molding region 801s is formed on the inner side by moving the ultraviolet irradiation unit 500 relative to the outer shape of the molded body 900A shown in FIG. 29 while irradiating the ultraviolet ray UV. A first mold layer 801 as a single molded article layer is formed. And it transfers to a single layer injection molding process.

(Single layer injection molding process)
In the single-layer injection molding step (S102), the first molding die layer 801 as the first molding single layer formed by the ultraviolet irradiation step (S12) on the forming surface 410a of the table 410 is used as a mold frame. A single layer as a part of the molded body 900A is injection molded. FIG. 31 shows a detailed flowchart of the single-layer injection molding step (S102).

(Insertion member supply determination process)
In the single layer injection molding step (S102), first, an insertion member supply determination step (S121) for determining whether or not the insertion member Ti included in the molded body 900A shown in FIG. Executed. In the insertion member supply determination step (S121), when it is determined that the insertion member Ti is supplied (YES) based on the control signal from the control unit 700A, the process proceeds to the insertion member supply step (S122) described later. When it is determined that the insertion member Ti is not supplied (NO), the table is moved to the injection molding start position (S123).
Information (control signal) formed without including the insertion member Ti is sent from the control unit 700A to the first single layer constituting the molded body 900A of this example, and the insertion member Ti is not supplied (NO). And the process proceeds to the step of driving the table to the injection molding start position (S123).

(Driving the table to the injection molding start position)
As shown in FIG. 32, the stage 200 is driven so that the injection port 620b of the injection unit 600 is disposed at the injection molding start position as a relative position with respect to the table 410. The table is driven to the injection molding start position (S123). Executed. At this time, the stage 200 is driven without changing the depth D _L1 of the formation surface 410a of the table 410 from the liquid surface Sf of the liquid resin material Mf.

(Injection molding process)
When the step of driving the table to the injection molding start position (S123) is executed, the table is transported to the injection port 620b of the injection unit 600 in the preparation process, and heated to the glass transition point or more by the heater provided in the injection unit 600. As shown in FIG. 33, an injection molding step (S124) is performed in which the resin material Mp thus formed is injected from the injection port 620b toward the table 410 with a predetermined pressure. At this time, the resin material Mp is injected and filled into a molding region 801 s which is a cavity formed inside the first molding die layer 801 formed in the mold molding single layer forming step (S 1).

33. Since the state of injection of the resin material Mp from the injection port 620b of the injection unit 600 shown in FIG. 33 is the same as that of the first embodiment, description thereof is omitted.

As described above, the injection unit 600 provided in the resin molding apparatus 1000A according to the third embodiment used in the resin molding method according to the present embodiment is a method of injecting the plastic resin Mpf by applying pressure from the injection port 620b. This is one embodiment of a so-called injection molding method.

Then, as shown in FIG. 34, while injecting the plasticized resin material Mp from the injection port 620b, the stage 200 is driven so that the injection unit 600 moves along a predetermined path relative to the table 410, and the first part is driven. The resin material Mp is disposed in a molding region 801s constituted by the molding die layer 801, and a first molding layer 901 as a first molding single layer is formed. In the present embodiment, since the formation of the molded body 900A shown in FIG. 29 is exemplified, the first molded layer 901 corresponds to the bottom of the molded body 900A and is formed in a flat plate shape.

When the first molding layer 901 of the first layer is formed, the injection molding process (S124) in the single-layer injection molding process (S102) is completed, and then the process proceeds to the stacking number confirmation process (S103).

(Stacking number confirmation process)
In the resin molding method according to the present embodiment, the first molded mold layer 801 and the single layer of the first molded layer 901 are stacked up to N layers (N: a natural number of 1 or more) to form a molded body 900A. . Therefore, the uppermost molded product single layer formed in the single layer injection molding step (S102) immediately before the number of laminated product confirmation step (S103) is confirmed, and the molded product single layer is laminated up to a predetermined number of laminated layers (N layers). A stacking number confirmation step (S103) for determining whether or not it has been performed is executed.

When it is determined in the number-of-stacks confirmation step (S103) that the molded product single layer formed in the immediately preceding single-layer injection molding step (S102) has not been formed to a predetermined number of layers (N layers), in other words, the number of layers When it is determined that the number is smaller than N (NO), the process proceeds to the stacking step (S104).

(Lamination process)
The lamination step (S104) in the resin molding method according to the present embodiment is a command step for repeatedly executing the molded product single layer formation step (S1) and the single layer injection molding step (S102), and confirms the number of layers. Mold molding lamination step (S41) for instructing repetition of the mold molding single layer forming step (S1) for newly forming a molding single layer on the uppermost mold molding single layer confirmed in the step (S103) ), And a molding lamination step (S102) for instructing repetition of a single layer injection molding step (S102) for newly forming a molding single layer on the uppermost molding single layer confirmed in the lamination number confirmation step (S103) ( S142). In accordance with a command issued in the mold molding lamination step (S41) included in the lamination step (S104), a new molding single layer is molded on the uppermost mold molding single layer already formed on the table 410. The process proceeds to the molded product single layer forming step (S1).

In the mold product single layer forming step (S1) executed based on the command of the mold product stacking step (S41) included in the stacking step (S104), first, the step of driving the table to the molding start position (S11) is executed. Is done. As shown in FIG. 35, in the step of driving the table to the molding start position (S11), the upper surface of the first mold layer 801 as the first mold molded product single layer formed on the table 410 and the ultraviolet irradiation unit The relative positions of the table 410 and the ultraviolet irradiation unit 500 are set so that the 500 ultraviolet emitting units 500a have a distance Duv. The interval Duv in the step (S11) of driving the table related to the stacking step (S104) to the molding start position is the liquid resin material Mf directly above the first mold layer 801 by the ultraviolet UV irradiated from the ultraviolet irradiation unit 500. Is the distance that can be reached as energy that can be cured. Then, the table 410 and the storage tank 300 are positioned relative to each other so that the upper surface of the first mold layer 801 is at a depth D _L2 from the liquid surface Sf of the liquid resin material Mf. Move. The depth D _L2 is the molding thickness of the second layer of the molded product single layer.

Next, the process proceeds to the ultraviolet irradiation step (S12). In the ultraviolet irradiation step (S12) related to the mold product lamination step (S41) included in the lamination step (S104), the ultraviolet ray UV irradiation unit 500 irradiates ultraviolet rays UV while maintaining the depth D _L2 as shown in FIG. The stage 200 is driven so that the ultraviolet irradiation unit 500 moves relative to the table 410 and follows the shape of the molded body 900A. And the 2nd shaping | molding die layer 802 as a 2nd 2nd shaping | molding molding single layer is formed by the ultraviolet irradiation part 500 moving relatively, irradiating ultraviolet-ray UV. The second mold layer 802 includes a second molded outer mold layer 802a for forming the outer shape of the molded body 900A and a second molded inner mold layer 802b for forming the inner side of the molded body 900A. The The second molding outer mold layer 802a is laminated on the first first molding mold layer 801, but the molded body 900A exemplified in this embodiment is formed by the first molding layer 901 serving as a flat bottom. Therefore, the second molded inner mold layer 802b is laminated on the first molded layer 901. And the 2nd molding area | region 802s enclosed by the 2nd shaping | molding outer mold layer 802a and the 2nd shaping | molding inner mold layer 802b is comprised.

Subsequently, a single-layer injection molding step (S102) related to the molded product laminating step (S142) included in the laminating step (S104) is executed, and the second layer is formed on the first molded layer 901 as the first molded product single layer. The second molded product single layer is formed. In the single-layer injection molding step (S102) related to the stacking step (S104), first, an insertion member supply determination step (S121) for determining whether or not to supply (insert) the insertion member Ti into the single layer is executed. In this example, since it is a molded body 900A in which the insertion member Ti is inserted into the second second molding single layer, the insertion member Ti is inserted based on the control signal from the control unit 700A (YES). It determines, and it transfers to an insertion member supply process (S122).

(Insertion member supply process)
In the insertion step supply step (S122), the insertion member Ti accommodated in the member tray 2100 shown in FIG. 20 is gripped by the hand portion 2000c of the robot 2000 and conveyed to a predetermined position. And as shown in FIG. 37, insertion member Ti is mounted in the predetermined position in the area | region of the shaping | molding area | region 802s of the 2nd layer.

Then, as shown in FIG. 38, the injection port of the injection unit 600 is opposed to the molding region 802s of the second molding die layer 802 formed by the mold product single layer forming step (S1) according to the stacking step (S104). While the 620b is moved relative to the table 410, the resin material Mp plasticized from the injection port 620b is constituted by the insertion member Ti placed in the molding region 802s and the molding region 802s. Inject into the space area. Then, the second molded layer 902 as the second molded product single layer of the second layer constituting the molded body 900A is formed by the injected resin material Mp and the insertion member Ti.

When the second molding layer 902 is formed by the single layer injection molding step (S102) related to the molding lamination step (S142) included in the lamination step (S104), the process proceeds to the lamination number confirmation step (S103), and the number of laminations is confirmed. It is determined whether or not the molded product single layer formed in the single layer injection molding step (S102) immediately before the step (S103) has been laminated up to a predetermined number of layers (N layers). And when it determines with the number of lamination | stacking of the molded object single layer formed by the immediately preceding single layer injection molding process (S102) being smaller than N (NO), it transfers to a lamination process (S104) again.

In the above-described laminating step (S104), the first mold single layer, the second mold single layer, the first mold single layer, and the first single mold second layer, The second means simply the order, not the number of layers. For example, when the fourth mold layer 804 as the fourth layer is laminated on the third mold layer 803 as the third layer, the third mold layer 803 is referred to as a first mold product single layer, and the fourth mold is formed. The mold layer 804 is referred to as a second mold product single layer. Similarly, when the fourth molded layer 904 of the fourth layer is laminated on the third molded layer 903 of the third layer, the third molded layer 903 is called a first molded product single layer, and the fourth molded layer 904 is This is called the second molded product single layer.

The molded body 900A formed by the resin molding method according to the present embodiment includes two insertion members Ti as shown in FIG. In this example, one insertion member Ti is included in the second second molding layer 902, and the second n-th molding layer 90n (n is a natural number equal to or greater than 1 and n ≦ N) is the second one. In the single layer injection molding step (S102) related to the stacking step (S104) for forming the nth layer, it is determined YES in the insertion member supply determination step (S121), and the insertion member supply step (S121) S122) is executed.

As shown in FIG. 39, the stacking step (S104) is repeated a predetermined number of times, and as shown in FIG. 39, as a mold body in which N layers are laminated from the first mold layer 801 to the Nth mold layer 80N of a single molded product. Using the first molded body 800A and the first molded body 800A as a molding die, the resin material Mp is injected into the so-called cavity in the molding regions 801s, 802s, 803s,. To a N-th molded layer 90N, a molded body 900A is formed as a second molded body in which N layers are stacked.

Further, in the molded body 900A obtained by the resin molding method according to the present embodiment, the insertion member Ti is integrally inserted into the molding layers 902 and 90n of the second layer and the n-th layer. . This is a resin molding method called so-called insert molding. And it transfers to the number-of-stacks confirmation process (S103), and when it determines with the formed molded object single layer having been laminated | stacked to the predetermined number of layers (N layer) (YES), it will transfer to a mold release process.

(Release process)
The mold release step (S5) is a step of separating the molded body 900A from the first molded body 800A and taking out the molded body 900A. Since the release step (S5) is the same as that of the molded body 900 of the first embodiment, detailed description thereof is omitted.

The resin molding method according to the fourth embodiment by the resin molding apparatus 1000A according to the third embodiment is a known three-dimensional resin molding in which an injection molding die for obtaining a molded body 900A uses a resin that is cured by energy rays. It is formed as a resin mold by the method. As a result, it is possible to achieve a significant reduction in mold production time and a reduction in equipment costs by eliminating the need for a metal processing apparatus for mold production.

Further, the molded body 900A including the insertion member Ti obtained by the resin molding method according to the present embodiment realizes a configuration in which the insertion member Ti cannot be visually recognized from the appearance of the molded body 900A as illustrated in FIG. is doing.

On the other hand, in a so-called insert molding method in injection molding using a conventional mold, an insert member is previously placed and fixed in a cavity of the mold, and then a resin is injected and injected into the cavity to mold a product. It was a method. For this reason, the insert member is integrally formed in a state that is visible from the appearance of the product, and the so-called insert member is an outsert product.

Alternatively, if a configuration in which the same insertion member as the molded body 900A obtained by the resin molding method according to the present embodiment cannot be visually recognized is obtained by an injection molding method using a conventional mold, the molded product is divided. It will be molded. That is, a part of a resin product is injection-molded by a mold, and a part is formed by placing and fixing an insertion member on a part of the molded product. Then, the part is placed and fixed on a mold for product molding, and a resin is injected into a cavity constituted by the part and the mold, so that it can be formed into a product shape.

However, in the product molding including the insertion member according to the above-described conventional method, the insertion member is a exposed product or requires a lot of man-hours by injection molding using a plurality of molds. . However, the resin molding method according to this embodiment does not require a mold and can easily obtain a molded body that includes the insertion member without exposing the insertion member.

Although the molded body 900A obtained by the resin molding method according to the above-described fourth embodiment exemplifies a form in which two identical insertion members Ti are included, the present invention is not limited to this. For example, there may be three or more, different shapes, or different materials.

(Fifth embodiment)
FIG. 40 is a configuration diagram showing a schematic configuration of a resin molding apparatus according to the fifth embodiment. The resin molding apparatus 1000B shown in FIG. 40 stores a stage 200 and a liquid resin material Mf as a liquid cured resin material that is installed on the stage 200 and includes an energy ray curable resin that is cured by being irradiated with energy rays. The storage tank 300 in which the storage space 300a is formed and the base 100 including a stage driving device (not shown) that drives the stage 200 three-dimensionally are provided. The three-dimensional drive is capable of driving in any of the X, Y, and Z directions shown in the figure.

In the storage space 300a of the storage tank 300, a molding unit 400 including a table 410 having a molded product formation surface 410a (hereinafter referred to as a formation surface 410a) and a drive shaft 420 that drives the table 410 in the Z-axis direction. Has been placed.

As described above, in the resin molding apparatus 1000B, the storage tank 300 stores the liquid resin material Mf containing the energy beam curable resin as the cured resin material, and is cured on the formation surface 410a by the energy beam as described later. Since the cured layer is formed and laminated, the liquid upper surface of the liquid resin material Mf and the formation surface 410a are arranged substantially in parallel. Therefore, it can be said that the Z-axis direction shown in the drawing is a so-called gravity direction, and the table 410 is driven in the gravity direction.

An energy ray irradiating unit 500 that irradiates energy rays toward the liquid upper surface of the liquid resin material Mf is disposed at the upper part in the gravity direction of the storage tank 300. In the resin molding apparatus 1000B according to the present embodiment, ultraviolet rays will be exemplified and described as energy rays. Therefore, the energy beam irradiation unit 500 will be described as the ultraviolet irradiation unit 500 below.
The energy beam for curing the energy beam curable resin is not limited to ultraviolet rays, and may be high frequency, radiation, or other energy beam that imparts energy for curing the irradiated object.

In addition, a first injection unit 601 (hereinafter, referred to as a plastic material) that plasticizes and injects a resin material Mp1 as a first material, which is a synthetic resin that is a material constituting a part of the product, in the upper part in the gravity direction of the storage tank 300. A first injection unit 601) and a second injection unit 602 (hereinafter referred to as a second injection unit) 602 that plasticizes and injects a resin material Mp2 as a second material that is a synthetic resin that constitutes the other part of the product. The injection unit 602) is arranged. In the present embodiment, an explanation will be given by exemplifying injection units 601 and 602 each including a flat screw.

Since the first injection unit 601 and the second injection unit 602 exemplify the same device configuration, the configuration of the first injection unit 601 will be described. The first injection unit 601 includes a heater (heating means) (not shown) and has a cylinder 612 having an internal space, a flat screw 613 disposed in the internal space of the cylinder 612, and a drive device that rotationally drives at least the flat screw 613. 614 and a material supply unit 611 that supplies the pellet-shaped resin material Mp1 to the internal space of the cylinder 612.

The pellet-shaped resin material Mp1 supplied to the cylinder 612 is heated to a temperature equal to or higher than the glass transition point by a heater provided in the cylinder 612 to become a plasticized resin material Mp1. The plasticized resin material Mp1 is sent to the injection port 612b by rotating the flat screw 613, and is injected from the injection port 612b.

The injection principle of the resin material Mp1 by the flat screw 613 is that the pellet-shaped resin material Mp1 is conveyed from the material supply unit 611 to the material inlet 612a of the cylinder 612 and plasticized by the heater of the cylinder 612. The plasticized resin material Mp1 is formed in a spiral shape from the outside of the flat screw 613 toward the rotation center 613r when the flat screw 613 is rotated around the rotation center 613r by the driving device 614. The plasticized resin material Mp is transported under pressure toward the rotation center 613r along the transport groove 613a, and is injected from the injection port 612b by the pressure.

In the resin molding apparatus 1000B according to the present embodiment, the second injection unit 602 also includes the same components as the first injection unit 601, and includes a material supply unit 621, a cylinder 622, a flat screw 623, and a driving device 624. ing. Then, the resin material Mp2 is injected from the injection port 622b. In addition, it is not limited that the 1st injection | emission part 601 and the 2nd injection | emission part 602 are provided with the same component. It is sufficient that at least different resin materials Mp1 and Mp2 can be injected.

As described above, it is preferable to use a thermoplastic resin for the resin material Mp1 injected from the first injection unit 601 and the resin material Mp2 injected from the second injection unit 602. Also, different resin materials can be used for the resin material Mp1 and the resin material Mp2. Different resin materials refer to resin materials that are not exactly the same, such as when the resin composition is different, or even when the physical properties of the same composition are different, such as color tone, hardness, and glass transition point.

The resin molding apparatus 1000B according to the present embodiment includes a control unit 700B, a stage controller 710 that controls driving of a stage driving device (not shown) included in the base 100, and molding that is driven in the gravity direction in the storage tank 300. Injection that controls a table controller 720 that controls a table driving device (not shown) that drives the unit 400, an ultraviolet irradiation control unit 730 that controls the ultraviolet irradiation unit 500, a first injection unit 601, and a second injection unit 602. The control unit 740B is controlled.

41 to 44 are diagrams for explaining the driving of the resin molding apparatus 1000B. FIG. 41 is a schematic configuration diagram showing a resin molding preparation stage by the resin molding apparatus 1000B. As shown in FIG. 41, in the resin molding preparation stage of the resin molding apparatus 1000B, the liquid resin material Mf that generates a cured product by irradiating the storage space 300a of the storage tank 300 with ultraviolet rays UV as energy rays is used. Store.

Then, the formation surface 410a of the table 410 is submerged in a depth D _L1 from the liquid surface Sf of the stored liquid resin material Mf. The depth D _L1 is the amount of sinking of the table 410 required to obtain the thickness of the first layer of the molded product to be described later.

In the first injection unit 601 and the second injection unit 602, pellet-shaped resin materials Mp1 and Mp2 are introduced from the hoppers 611a and 621a of the material supply units 611 and 621 and are conveyed to the cylinders 612 and 622. In the cylinders 612 and 622, the resin materials Mp1 and Mp2 are heated to a temperature exceeding the glass transition point by a heater (not shown) and plasticized. The resin materials Mp1 and Mp2 plasticized by the rotation of the flat screws 613 and 623 are pressurized and conveyed to the injection ports 612b and 622b.

When preparation for resin molding of the resin molding apparatus 1000B shown in FIG. 41 is completed, ultraviolet rays UV as energy rays are emitted from the ultraviolet irradiation port of the ultraviolet irradiation unit 500 toward the liquid surface Sf of the liquid resin material Mf as shown in FIG. Is irradiated. The stage 200 is driven in the XY direction relative to the ultraviolet irradiation unit 500 by a stage driving device (not shown) provided in the base 100 in synchronization with the irradiation of the ultraviolet UV, and is stored in the stage 200. 300 is moved relative to the ultraviolet irradiation unit 500 in the XY direction. The liquid resin material Mf is cured by being irradiated with ultraviolet rays UV, and a first first mold layer 810 having a thickness of D _L1 is formed on the formation surface 410a.

The resin material Mp1 plasticized from the injection port 612b of the first injection portion 601 is injected as shown in FIG. 43 into the molding region 810s surrounded by the first mold layer 810 described with reference to FIG. As a result, a first molded layer 911 as the second molded product of the first layer is formed on the forming surface 410a. In this example, the resin material Mp1 is injected from the first injection portion 601 with the inside of the first molding die layer 810 formed in a frame shape as the first molding region 810s, and the first molding layer 911 is formed. However, the first molding layer may be formed by injecting the resin material Mp2 from the second injection portion 602 into the molding region 810s. In this example, since the first molding layer 911 is a single layer of the resin material Mp1, the first molding layer 911 will be described as the first molding layer 910 below.

As described above, the resin molding apparatus 1000B according to the present embodiment cures the liquid resin material Mf with ultraviolet UV to form the first mold layer 810, and plasticizes the first mold layer 810 as a mold frame. The resin material Mp1 is injected from the injection portion 601 to form the first molding layer 910, thereby forming a layered molding. And it is an apparatus which forms the molding on the formation surface 410a of the table 410 by repeatedly forming the layered molding and laminating it.

44 and 45 show a form in which a second molding die layer 820 for forming a second second molding layer laminated on the first molding layer 910 described later is formed. The second mold layer 820 is formed by forming a plurality of layers, that is, the connection layer 820a shown in FIG. 44 and the upper layer 820b shown in FIG.

As shown in FIG. 44, a connection layer 820a constituting the second mold layer 820 is formed. The formation surface 410a of the table 410 is set so that the upper surface 810f of the first mold layer 810 is submerged in the depth D _L2A from the liquid surface Sf of the liquid resin material Mf so as to have a depth corresponding to the thickness of the connection layer 820a. Move.

The connection layer 820a includes a frame-shaped first connection layer 821a and a frame-shaped second connection layer 822a disposed inside the first connection layer 821a in the direction of the arrow along the Z-axis from above in the drawing, A third connection layer 823a is formed between the first connection layer 821a and the second connection layer 822a. An upper layer 820b is formed on the formed connection layer 820a.

As shown in FIG. 45, the table 410 is formed so that the upper surface 82Af of the connection layer 820a is submerged in the depth D _L2B from the liquid surface Sf of the liquid resin material Mf so as to have a depth corresponding to the thickness of the upper layer 820b. The surface 410a is moved. Then, the upper layer having a thickness of D _L2B is obtained by irradiating the ultraviolet resin UV from the ultraviolet irradiation unit 500 toward the liquid resin material Mf and moving the storage tank 300 arranged in the stage 200 in the relative XY directions. 820b is formed on the connection layer 820a having a thickness of D _L2A , and a second mold layer 820 as a second first molded product having a thickness of D _L20 is formed.

In the upper layer 820b, the first upper layer 821b is formed so as to overlap the first connection layer 821a and the second upper layer 822b is formed so as to overlap the second connection layer 822a when viewed in the direction of the arrow along the Z-axis from above the drawing. The In this example, a mode in which no upper layer is formed on the third connection layer 823a will be described.

The connection layer 820a and the upper layer 820b are laminated to form the second mold layer 820. Between the laminate of the first connection layer 821a and the first upper layer 821b formed in a frame shape, and the laminate of the second connection layer 822a and the second upper layer 822b formed in a frame shape Thus, a molding region 820s of the second-layer molded body is configured. The molding region 820s includes a first molding region 82As and a second molding region 82Bs that substantially have the formation portion of the third connection layer 823a as a boundary.

As shown in FIG. 46, as the first material from the first injection portion 601, the molding region 820 s configured in the second mold layer 820 as the first molded product of the second layer shown in FIG. 45 is used. Resin material Mp1 is injected. The injected resin material Mp1 is controlled to an amount capable of filling the first molding region 82As, and the first molding layer 921 is formed as the molding layer of the resin material Mp1 in the second molding layer 920 of the second layer. .

At this time, the third connection layer 823a disposed in the molding region 820s protrudes beyond the first molding region 82As, which is the molding region of the resin material Mp1, into the injected resin material Mp1 and into the second molding region 82Bs. To suppress that. Moreover, the inner peripheral surface of the second molding die layer 820 of the first molding layer 921 is suppressed by protruding beyond the first molding region 82As that is the molding region of the resin material Mp1 to the second molding region 82Bs. Transferability to the shape can be improved.

Subsequently, as shown in FIG. 47, the injection port 622b of the second injection portion 602 is relatively moved to a position corresponding to the second molding region 82Bs not filled with the resin material, and the resin material Mp2 is injected. . The injected resin material Mp2 is controlled to an amount capable of filling the second molding region 82Bs, and the second molding layer 922 is formed as the molding layer of the resin material Mp2 in the second second molding layer 920. . At this time, the second molding region 82Bs is formed by the third connection layer 823a disposed in the molding region 820s and the first molding layer 921 formed with the resin material Mp1, and the second molding layer 922 is formed. Transferability of the second mold layer 820 to the inner peripheral surface shape can be improved.

Thus, two layers are formed in the molding region 820s of the second mold layer 820 by the first molding layer 921 formed of the resin material Mp1 and the second molding layer 922 formed of the resin material Mp2. A second molded layer 920 of the eye is formed and laminated to the first molded layer 910.

48, the third mold layer 830 and the third mold layer 930 are stacked on top of the formed second mold layer 820 and the second mold layer 920, respectively. Further, the molding is repeated, and the N-th N-th molding layer 8N0 and the N-th molding layer 9N0 are laminated as the uppermost layer, and are formed by the first molded body 800B and the first molded body 800B. A so-called cavity is filled with the resin material Mp1 and the resin material Mp2, and the second molded body 900B is formed.

The second molded body 900B can be said to be a so-called two-color molded product in which the resin material Mp1 and the resin material Mp2 are integrally molded in this example. In addition, although the resin molding apparatus 1000B according to the present embodiment has been described as a configuration including the two injection units of the first injection unit 601 and the second injection unit 602, the present invention is not limited thereto, and three or more It may be a resin molding device provided with an injection part. Further, it is preferable to use different materials for the resin material Mp1 and the resin material Mp2, but the same resin material can also be used.

As described above, the first molded body 800B is a molding resin mold in which a cavity that is a space for molding the second molded body 900B is formed. Therefore, it is not necessary to prepare an expensive metal mold for manufacturing the second molded body 900B as a product, that is, a so-called mold, and the liquid resin material Mf is easily cured by ultraviolet rays UV as energy rays. Solid modeling, so-called 3D modeling, is possible. The second molded body 900B as a product is formed by so-called injection molding, in which the resin materials Mp1 and Mp2 of thermoplastic resin are injected from the injection portions 601 and 602, and the first molded body 800B is molded as a molding die. Can do. Therefore, the resin materials Mp1 and Mp2 may be thermoplastic resins. This is because, conventionally, in a modeling apparatus that generally performs 3D modeling using an ultraviolet curable resin, the resin material of the product is limited to the ultraviolet curable resin. In other words, if a resin that cannot be cured by ultraviolet rays is designated as the product resin, it is necessary to rely on injection molding using a mold.

According to the resin molding apparatus 1000B according to the present embodiment, a mold for injection molding of a thermoplastic resin can be molded with an energy ray curable resin capable of 3D modeling in a short time and at a low cost. Therefore, even when a resin material that cannot be applied to the energy beam curable resin is used, an expensive metal mold is not created, and therefore, resin molding can be performed in a short time and at a low cost.

Furthermore, the resin molding apparatus 1000B according to the present embodiment is a second molded body 900B that is so-called two-color molded, which is composite-molded with a plurality of resin materials, in this example, two types of resin materials Mp1 and Mp2. Even when a resin material that cannot be applied to the energy beam curable resin is used, an expensive metal mold is not created, and therefore, resin molding can be performed in a short time and at a low cost.

(Sixth embodiment)
As a sixth embodiment, an embodiment of a resin molding method using a resin molding apparatus 1000B according to the fifth embodiment will be described. FIG. 49 is a flowchart of a resin molding method according to the sixth embodiment. In the flowchart shown in FIG. 49, as a preparation for manufacturing, a predetermined amount of the liquid resin material Mf is stored in the storage tank 300 provided in the resin molding apparatus 1000B, and the pellet-shaped resin is stored in the material supply unit 611 of the first injection unit 601. The material Mp1 is supplied to the material supply unit 621 of the second injection unit 602 as a pellet-shaped resin material Mp2. Then, the resin materials Mp1 and Mp2 heated and plasticized by a heater (not shown) provided in the cylinders 612 and 622 are advanced to a state where they are conveyed to the injection ports 612b and 622b. This manufacturing preparation is completed, and the flowchart shown in FIG. 49 is started.

In addition, the description of the resin molding method according to the sixth embodiment describes a method of molding the second molded body 900B described in the fifth embodiment, taking the form shown in the external perspective view of FIG. 50 as an example. Hereinafter, the second molded body 900B is referred to as a molded body 900B. As shown in FIG. 50, the molded body 900B includes a first molded body 901B having a cross-sectional shape of a first cross section 901Ba molded by a resin material Mp1 as a first material, and a resin material as a second material. The container which has the external shape of the truncated cone which has cross-sectional shape 900Ba provided with 2nd molded object 902B which has the cross-sectional shape of 2nd cross-section 902Ba shape | molded by Mp2, and an inner space is illustrated.

(Molded product single layer forming process)
First, a molded product single layer forming step (S201) is performed. FIG. 51 shows a detailed flowchart of the molded product single layer forming step (S201).

(The stage / table is driven to the molding start position)
The storage tank 300 in which the liquid resin material Mf is stored in the preparation step described above and the table 410 provided in the storage tank 300 are driven by the stage driving device provided in the base 100, and the table is driven to the molding start position ( Step S211) is executed. In the step of driving the table to the molding start position (S211), as shown in FIG. 52, the interval Duv between the forming surface 410a of the table 410 and the ultraviolet emitting unit 500a of the ultraviolet irradiating unit 500 is set to a predetermined interval. The relative position between the table 410 and the ultraviolet irradiation unit 500 is set. The predetermined interval of the interval Duv is a distance that the ultraviolet ray UV irradiated from the ultraviolet irradiation unit 500 can reach as the energy that can cure the liquid resin material Mf just above the formation surface 410a. And the table 410 and the storage tank 300 are moved to the position where the formation surface 410a becomes the depth D _L1A from the liquid surface Sf of the liquid resin material Mf. The depth D _L1A is a layer to be molded first, and is the molding thickness of the first connection layer formed on the formation surface 410a described later.

(UV irradiation process)
When the ultraviolet irradiation unit 500 is disposed at a predetermined relative position with respect to the table 410, an ultraviolet irradiation step (S212) is executed. The ultraviolet irradiation step (S212) includes a connection layer formation step (S2121), an upper layer formation step (S2122), and an upper layer stacking number confirmation step (S2123). In the resin molding method according to the present embodiment, a single mold layer is formed by laminating a plurality of single layers. Therefore, in the ultraviolet irradiation step (S212), a connection layer forming step (S2121) is first executed. As shown in FIG. 53, the stage 200 is driven so that the ultraviolet irradiation unit 500 moves relative to the table 410 while irradiating the ultraviolet ray UV from the ultraviolet irradiation unit 500 while maintaining the depth D _L1A . The first mold layer 810 as a first mold molded product single layer is constructed by moving the ultraviolet irradiation unit 500 relative to the outer shape of the molded body 900B shown in FIG. A connecting layer 810a is formed.

When the connection layer 810a is formed, the process proceeds to the upper layer formation step (S2122). In the upper layer formation step (S2122), as shown in FIG. 54, the relative position between the table 410 and the storage tank 300 is set such that the upper surface of the connection layer 810a is at the depth D _L1B from the liquid surface Sf of the liquid resin material Mf. The table 410 and the storage tank 300 are moved. The depth D _L1B is the formation thickness of the upper layer stacked on the connection layer 810a.

Then, as shown in FIG. 55, the upper layer 810b is formed by curing the liquid resin material Mf by irradiating the connection layer 810a with ultraviolet rays UV from the ultraviolet irradiation section 500. When the upper layer 810b is formed by the upper layer formation step (S2122), the process proceeds to the upper layer stacking number confirmation step (S2123). In this example, the form of the two-layer configuration of the connection layer 810a and the upper layer 810b is illustrated. Accordingly, the upper layer stacking number is one layer, which is compared with the upper layer stacking number (predetermined upper layer stacking number) of the formation control data read in advance by the control unit 700B (see FIG. 40). Since it is the same case (YES), the ultraviolet irradiation step (S212) is terminated and the process proceeds to the next single-layer injection molding step (S202).

In the upper layer stacking number confirmation step (S2123), when the upper layer stacking number is less than the upper layer stacking number of the formation control data (NO), the process proceeds to the upper layer forming step (S2122) again. In the upper layer forming step (S2122), the upper layer is stacked on the previously formed upper layer, and in the upper layer stacking number confirmation step (S2123), the upper layer stacking number reaches the upper layer stacking number of the formation control data (YES). The ultraviolet irradiation process (S212) ends, and the process proceeds to the next single-layer injection molding process (S202). In the resin molding method according to this embodiment exemplified above, the upper layer stacking number is one layer. However, the present invention is not limited to this, and a plurality of layers may be stacked. Further, the number of upper layers may be zero, that is, the ultraviolet irradiation step (S212) may be completed with one layer of the connection layer 810a.

(Single layer injection molding process)
In the single-layer injection molding step (S202), the first molding die layer 810 as a single layer of the first molded product formed by the ultraviolet irradiation step (S212) is formed on the forming surface 410a of the table 410 as a mold frame. A single layer as a part of the molded body 900B is injection-molded in the molded region 810s. FIG. 56 shows a detailed flowchart of the single-layer injection molding step (S202).

(First injection molding process execution necessity confirmation process)
The resin molding method according to the present embodiment is a resin molding method using the resin molding apparatus 1000B according to the fifth embodiment, and includes a first injection unit 601 and a second injection unit 602 as shown in FIG. Since the two injection parts are provided, in the single-layer injection molding step (S202), first, it is confirmed whether or not the first injection molding step as the first single-layer injection molding step is necessary. An injection molding step execution necessity confirmation step (S221) is executed.
In the first injection molding step execution necessity confirmation step (S221), whether or not to drive (execute) injection of the resin material Mp1 as the first material from the first injection unit 601 is determined in advance by the control unit 700B (FIG. 40)) from the formation control data read.

In the first injection molding step execution necessity confirmation step (S221), when the first layer molding region 810s is not the injection region of the resin material Mp1 as the first material injected from the first injection unit 601, It is determined that the injection molding of the resin material Mp1 by the first injection unit 601 is not executed (NO), and the second injection for confirming the necessity of executing the second injection molding process as the second single-layer injection molding process to be described later The process proceeds to the molding process execution necessity confirmation process (S224).

In the resin molding method according to the present embodiment, since the molding region 810s is exemplified as the region filled with the resin material Mp1, the first injection part 601 starts from the first injection molding step execution necessity confirmation step (S221). It is determined that the injection of the resin material Mp1 is to be executed (YES), and the table 410 is driven to the injection molding start position.

(Driving the table to the injection molding start position by the first injection part)
As shown in FIG. 57, the table is driven by the first injection unit to drive the stage 200 so that the injection port 612b of the first injection unit 601 is disposed at the injection molding start position as a relative position to the table 410. Drive to the start position (S222) is executed. In this case, the depth D _L10 from the liquid surface Sf of the liquid resin material Mf of forming surface 410a of the table 410 is a stage 200 without changing driven.

(First injection molding process)
When the step of driving the table to the injection molding start position by the first injection unit (S222) is executed, the heater is transported to the injection port 612b of the first injection unit 601 in the preparation process, and is provided in the first injection unit 601. As shown in FIG. 58, the resin material Mp1 heated and plasticized to a temperature above the glass transition point is injected from the injection port 612b toward the table 410 by a predetermined pressure. At this time, the first single unit in which the resin material Mp1 is injected and filled into the molding region 810s serving as the cavity formed inside the first molding die layer 810 formed in the mold molding single layer forming step (S201). A first injection molding step (S223) as a layer injection molding step is executed.

A state of injection of the resin material Mp1 from the injection port 612b of the first injection unit 601 shown in FIG. 58 will be described with reference to FIG. 59 of the B1 enlarged view. For convenience of explanation in FIG. 59, the plasticized resin material Mp1 is referred to as a plastic resin Mpf, and the resin material Mp1 solidified from the plasticized state is referred to as a solidified resin Mps.

As shown in FIG. 59, the plastic resin Mpf is pressurized by the rotational drive of the flat screw 613 and injected from the injection port 612b. The injected plastic resin Mpf is cooled to a temperature lower than the glass transition point in the process of reaching the formation surface 410a of the table 410, so that the form changes to the solidified resin Mps. The plastic resin Mpf is continuously laminated and solidified on the solidified resin Mps, and the solidified resin Mps is formed as a molded product in the molding region 810s of the first mold layer 810.

At this time, the uncured liquid resin material Mf remains inside the first mold layer 810 formed in a frame shape, that is, in the molding region 810s, so that the plastic resin Mpf remains as a liquid resin. It can be cooled by touching the material Mf to promote solidification to become a solidified resin Mps. Accordingly, it is possible to shorten the time of the plastic resin Mpf state on the forming surface 410a, to prevent unnecessary flow in the XY direction shown in the figure, so-called outflow, and to perform molding with an accurate shape. it can.

As described above, the first injection unit 601 included in the resin molding apparatus 1000B according to the fifth embodiment used in the resin molding method according to this embodiment injects the plastic resin Mpf by applying pressure from the injection port 612b. This is one embodiment of a so-called injection molding method. A second injection unit 602, which will be described later, is also an embodiment of an injection molding method for injecting the plastic resin Mpf by applying pressure from the injection port 622b.

Then, as shown in FIG. 60, the stage 200 is driven so that the first injection unit 601 moves along a predetermined path relative to the table 410 while injecting the plasticized resin material Mp1 from the injection port 612b. A resin material Mp1 is disposed in a molding region 810s constituted by the first molding die layer 810, and a first molding layer 910 as a first molded single layer is formed as a first layer, and a first injection molding step. (S223) ends. In the present embodiment, since the formation of the molded body 900B shown in FIG. 50 is exemplified, the first molded layer 910 corresponds to the bottom of the molded body 900B and is formed in a flat plate shape.

(Second injection molding process execution necessity confirmation process)
When the first injection molding step (S223) is completed, a second injection molding step execution necessity confirmation step (confirming necessity of execution of the second injection molding step as the second single-layer injection molding step) The process proceeds to S224). In the second injection molding step execution necessity confirmation step (S224), the resin material as the second material from the second injection portion 602 is the same as the first injection molding step execution necessity confirmation step (S221) described above. The necessity of driving (execution) for injecting Mp2 is determined from the formation control data read in advance by the control unit 700B (see FIG. 40).

In the second injection molding step execution necessity confirmation step (S224), when the first layer molding region 810s is not the injection region of the resin material Mp2 as the second material injected from the second injection portion 602, the first It is determined that the injection molding of the resin material Mp2 by the two-injection unit 602 is not performed (NO), the single-layer injection molding process (S202) ends, and the process proceeds to the stacking number confirmation process (S203).

In the second injection molding step execution necessity confirmation step (S224), the first layer molding region 810s is an injection region of the resin material Mp2 as the second material injected from the second injection portion 602. The injection molding of the resin material Mp2 by the second injection unit 602 is determined to be executed (YES). Then, the table is driven to the injection molding start position by the second injection unit (S225), and each step of the second injection molding step (S226) as the second single-layer injection molding step is executed.

In the resin manufacturing method according to the present embodiment, since the first molding layer 910 is formed of the resin material Mp1 as the first material, NO is determined in the second injection molding step execution necessity confirmation step (S224). Is determined, the single-layer injection molding step (S202) ends, and the process proceeds to the stacking number confirmation step (S203).

(Stacking number confirmation process)
In the resin molding method according to the present embodiment, the molded body 900B is formed by laminating a single layer of the first molding die layer 810 and the first molding layer 910 described above up to N layers (N: a natural number of 1 or more). . Therefore, the uppermost molded product single layer formed in the single-layer injection molding step (S202) immediately before the number of laminated product confirmation step (S203) is confirmed, and the molded product single layer is laminated to a predetermined number of laminated layers (N layers). A stacking number confirmation step (S203) for determining whether or not it has been performed is performed.

When it is determined in the number-of-stacks confirmation step (S203) that the molded product single layer formed in the immediately preceding single-layer injection molding step (S202) has not been formed to a predetermined number of layers (N layers), in other words, the number of layers When it is determined that the number is smaller than N (NO), the process proceeds to the stacking step (S204).

(Lamination process)
The lamination step (S204) in the resin molding method according to the present embodiment is a command step for repeatedly executing the mold product single layer formation step (S201) and the single layer injection molding step (S202), and confirms the number of layers. Mold molding stacking step (S241) for instructing repetition of the mold molding single layer forming step (S201) for newly forming a mold molding single layer on the uppermost mold molding single layer confirmed in the step (S203) ), And a molded product laminating step (S202) for instructing repetition of a single layer injection molding step (S202) for newly forming a molded single layer on the uppermost molded single layer confirmed in the number of layers confirmation step (S203) S242). In accordance with a command issued in the mold molding lamination step (S241) included in the lamination step (S204), a new molding single layer is molded on the uppermost mold molding single layer already formed on the table 410. The process proceeds to the molded product single layer forming step (S201).

(Driving the table to the molding start position)
In the mold product single layer forming step (S201) executed based on the command of the mold product stacking step (S241) included in the stacking step (S204), first, the step of driving the table to the molding start position (S211) is executed. Is done. As shown in FIG. 61, in the step of driving the table to the molding start position (S211), the upper surface of the first mold layer 810 as the first mold molded product single layer formed on the table 410, and the ultraviolet irradiation unit The relative positions of the table 410 and the ultraviolet irradiation unit 500 are set so that the 500 ultraviolet emitting units 500a have a distance Duv. The interval Duv in the step of driving the table related to the stacking step (S204) to the molding start position (S211) is the liquid resin material Mf immediately above the first mold layer 810 when the ultraviolet ray UV is irradiated from the ultraviolet irradiation unit 500. Is the distance that can be reached as energy that can be cured. Then, the table 410 and the storage tank 300 are moved relative to the table 410 and the storage tank 300 to a position where the upper surface of the first mold layer 810 is at the depth D _L2A from the liquid surface Sf of the liquid resin material Mf. The depth D _L2A is the molding thickness of the connection layer in the second layer of the molded product.

(UV irradiation process)
UV in the resin molding method according to this embodiment, the ultraviolet irradiation step in the second layer (S212) a connection layer forming step (S2121), by keeping the depth D _L2A as illustrated in FIG. 62 from the ultraviolet irradiation unit 500 While irradiating UV, the stage 200 is driven so that the ultraviolet irradiation unit 500 moves relative to the table 410, and the second mold layer 820 as a second layer of the second mold product is formed. A connection layer 820a to be formed is formed. The connection layer 820a includes a first connection layer 821a, a second connection layer 822a, and a third connection layer 823a serving as a boundary wall. At this time, a third connection layer 823a as a boundary wall for forming a boundary between the first molded body 901B and the second molded body 902B constituting the molded body 900B shown in FIG. 50 (see FIG. 44). Is formed. That is, the ultraviolet irradiation step (S212) includes a boundary wall layer forming step of forming the third connection layer 823a as a boundary wall.

The third connection layer 823a is formed in a region corresponding to the boundary between the first molded body 901B and the second molded body 902B constituting the molded body 900B as described above. The necessity of forming the boundary wall is set by formation control data read in advance by the control unit 700B (see FIG. 40). In the present embodiment, the molded body 900B shown in FIG. 50 is exemplified. Therefore, the third connection layer 823a serving as the boundary wall is formed.

When the connection layer 820a is formed, the process proceeds to the upper layer formation step (S2122). In the upper layer forming step (S2122), as shown in FIG. 63, the relative position between the table 410 and the storage tank 300 is set such that the upper surface of the connection layer 820a is at the depth D _L2B from the liquid surface Sf of the liquid resin material Mf. The table 410 and the storage tank 300 are moved. The depth D _L2B is the formation thickness of the upper layer stacked on the connection layer 820a.

Then, the upper layer 820b is formed by curing the liquid resin material Mf by irradiating the connection layer 820a with ultraviolet UV from the ultraviolet irradiation unit 500. In the present embodiment, no boundary wall is formed on the third connection layer 823a, which is a boundary wall formed by the connection layer 820a. Therefore, the upper layer 820b includes the first upper layer 821b and the second upper layer 822b, and the upper layer 820b is formed by the upper layer forming step (S2122).

The upper layer 820b formed by the upper layer formation step (S2122) and the connection layer 820a previously formed by the connection layer formation step (S2121) are the second layers as the second molded product single layer as the second layer. A mold layer 820 is formed. The second mold layer 820 forms a molding region 820s as a cavity of the second layer. The second layer molding region 820s sandwiches the molding region of the third connection layer 823a, which is a boundary wall, and the first molding region 82As serving as the first cavity region and the second molding region serving as the second cavity region. 2 molding regions 82Bs.

When the upper layer 820b is formed by the upper layer formation step (S2122), the process proceeds to the upper layer stacking number confirmation step (S2123). In this example, the form of the two-layer configuration of the connection layer 820a and the upper layer 820b is illustrated. Therefore, the number of upper layers is one layer, which is the same as “one layer” of the formation control data compared with the upper layer number of the formation control data read in advance by the control unit 700B (see FIG. 40) (YES). Therefore, the ultraviolet irradiation step (S212) is terminated, and the process proceeds to the next single-layer injection molding step (S202).

(Single layer injection molding process)
When the process proceeds to the single-layer injection molding step (S202), a first injection molding step execution necessity confirmation step (S221) is first executed.

(First injection molding process execution necessity confirmation process)
In the first injection molding step execution necessity confirmation step (S221), when the second molding layer 920 as the second molding single layer of the second layer is molded, it is read in advance into the control unit 700B (see FIG. 40). Whether or not driving (execution) of the first injection unit 601 is necessary is determined from the formed control data. In this embodiment, since it is a resin molding method of the molded body 900B having the first molded body 901B formed of the resin material Mp1, the first injection molding process execution necessity confirmation step (S221) is the first injection. It is determined that injection of the resin material Mp1 is performed from the part 601 (YES), and the table 410 is driven to the injection molding start position.

(Driving the table to the injection molding start position by the first injection part)
As shown in FIG. 64, the table 200 is driven by the first injection unit to drive the stage 200 so that the injection port 612b of the first injection unit 601 is disposed at the injection molding start position as a relative position to the table 410. Drive to the start position (S222) is executed. At this time, the stage 200 is not driven in the Z direction, and the depth (D _L1 + D _L2 ) from the liquid surface Sf to the formation surface 410a of the liquid resin material Mf is maintained, and the first injection molding step (S223) is performed. Migrated.

(First injection molding process)
In the first injection molding step (S223), as shown in FIG. 64 and FIG. 65 of the B2 enlarged view shown in FIG. 64, a second mold single layer forming step is performed from the injection port 612b by a predetermined pressure. The first injection molding step in which the resin material Mp1 is injected and filled in the first molding region 82As constituting the molding region 820s that becomes the cavity formed in the second molding die layer 820 formed in (S201). (S223) is executed.

The resin material Mp1 injected toward the first molding region 82As is cooled and solidified to form the second first molding layer 921. At this time, the injected and plasticized resin material Mp1 is prevented from entering the second molding region 82Bs where the second material Mp2 described later is injected by the third connection layer 823a serving as the boundary wall. . That is, the molding region of the third connection layer 823a can be formed by regulating the boundary region between the first molded body 901B and the second molded body 902B when the single-layer molded layer is formed. it can.

The resin material Mp1 is injected and filled in the first molding region 82As, the second first molding layer 921 is formed, the first injection molding step (S223) is completed, and the second injection molding step is executed. The process proceeds to the necessity confirmation step (S224).

(Second injection molding process execution necessity confirmation process)
Similar to the first injection molding step execution necessity confirmation step (S221), the second injection molding step execution necessity confirmation step (S224) related to the lamination step (S204) is performed by the second injection unit 602. The necessity of driving (execution) for injecting the resin material Mp2 as the material is determined from the formation control data read in advance by the control unit 700B (see FIG. 40). In this embodiment, since it is a resin molding method of the molded body 900B having the second molded body 902B formed of the resin material Mp2, the second injection molding process execution necessity confirmation step (S224) is performed in the second injection. It is determined that injection of the resin material Mp2 from the part 602 is executed (YES), and the table 410 is driven to the injection molding start position.

(Driving the table to the injection molding start position by the second injection part)
66, the table is driven by the second injection unit so that the stage 200 is driven so that the injection port 622b of the second injection unit 602 is disposed at the injection molding start position as a relative position to the table 410. Drive to the start position (S225) is executed. At this time, the stage 200 is not driven in the Z direction, and the depth (D _L1 + D _L2 ) from the liquid surface Sf of the liquid resin material Mf to the formation surface 410a is maintained, and the second injection molding step (S226) is performed. Migrated.

(Second injection molding process)
In the second injection molding step (S226), as shown in FIG. 66 and FIG. 67 of an enlarged view of the B3 portion shown in FIG. 66, a second layer of molded product single layer is formed from the injection port 622b with a predetermined pressure. Second injection molding step in which the resin material Mp2 is injected and filled into the second molding region 82Bs constituting the molding region 820s that becomes the cavity configured in the second molding die layer 820 formed in (S201). (S226) is executed.

The resin material Mp2 injected toward the second molding region 82Bs is cooled and solidified to form a second second molding layer 922. At this time, the injected plasticized resin material Mp2 is connected to the end portion 921a and constitutes a second molded layer 920 as a so-called two-color molded second molded product single layer. The end portion 921a is formed in a molding region of the third connection layer 823a that is a boundary wall of the first molding layer 921 formed by the first injection molding step (S223) executed previously. The resin material Mp2 is injected and filled in the second molding region 82Bs, and the second molding layer 920 is formed by forming the second molding layer 922 of the second layer, and the second injection molding step (S226). Is completed, and the process proceeds to the stacking number confirmation step (S203).

(Stacking number confirmation process)
In the single-layer injection molding step (S202) immediately before the number-of-stacks confirmation step (S203), the formed single-layer molded layer is confirmed, and the single-layer molded product is laminated to a predetermined number of layers (N layers). A stacking number confirmation step (S203) for determining whether or not has been performed is executed. In the stacking number confirmation step (S203) related to the above-described stacking step (S204), the number of stacks of the single layer of the molded product formed in the immediately preceding single layer injection molding step (S202) is the second first molding layer 910. The second molding layer 920 and the second molding layer 920 are determined to be smaller than the predetermined number N of layers (NO), and the process proceeds to the stacking step (S204) again.

In the above-described laminating step (S204), the first mold single layer, the second mold single layer, the first mold single layer, and the first mold single layer in the second mold single layer, The second means simply the order, not the number of layers. For example, when a fourth fourth mold layer 840 is laminated on the third mold layer 830, the third mold layer 830 is called a first mold single layer, and the fourth mold is formed. The mold layer 840 is referred to as a second mold product single layer. Similarly, when the fourth molded layer 940 as the fourth layer is laminated on the third molded layer 930 as the third layer, the third molded layer 930 is referred to as a first molded product single layer, and the fourth molded layer 940 is referred to as the first molded product single layer. This is called the second molded product single layer.

The lamination step (S204) is repeated a predetermined number of times. As shown in FIG. 68, from the first mold layer 810 including the connection layer 810a and the upper layer 810b, the connection layer 8N0a and the upper layer 8N0b A first molded body 800B as a molded body in which a single layer of a molded product up to the Nth molded mold layer 8N0 is laminated, and the first molded body 800B as a molding die to form an internal space, a so-called cavity. The resin material Mp1 and the resin material Mp2 are injected. The injection molded resin material Mp1 and the resin material Mp2 are configured by a first molded layer 910 configured by the first molded layer 911, a first molded layer 921, and a second molded layer 922. A molded body as a second molded body that is laminated up to an N-th molded layer 9N0 composed of the second molded layer 920 and the N-th first molded layer 9N1 and the second molded layer 9N2. 900B is formed.

As shown in FIG. 50, in the molded body 900B, a first molded body 901B and a second molded body 902B are integrally formed. Although not shown in FIG. 68, a first molded first layer is formed. The first molded body 901B is constituted by the first molded layer 9N1 of the Nth layer from the layer 911, and the second molded layer 9N2 of the Nth layer is formed by the second molded layer 922B of the second layer. A body 902B is constructed.

The molded body 900B includes a third connection layer 8N3a (not shown) included in the Nth Nth mold layer 8N0 from the third connection layer 823a included in the second second mold layer 820. The third connection layer included in each of the layers remains in the molded body 900B. And it transfers to the lamination | stacking number confirmation process (S203), it determines with the lamination | stacking number of the formed molded product single layer having been laminated | stacked to the N layer (YES), 1st molded object 800B, and 2nd molded object as The molded body 900B is taken out from the storage tank 300 and transferred to the mold release step.

(Release process)
The mold release step (S205) is a step of separating the molded body 900B from the first molded body 800B and taking out the molded body 900B. In the mold release step (S205), the first molded body 800 is separated by physical means or chemical means in the same manner as the mold release step (S5) of the first embodiment to obtain the molded body 900. it can. As described above, the connection layers 823a,..., 8N3a included in the first molded body 800B remain inside the molded body 900B.

The molded body 900B obtained by the resin molding method according to the present embodiment includes the third connection layers 823a,..., 8N3a remaining in the respective layers in the second molding layer 920 to the N-th molding layer 9N0 which are two-color molded portions. , 9N1 and the second molded layers 922, ..., 9N2 are formed, and the two-color molded body 900B formed of the resin materials Mp1, Mp2 is formed. Adhesive strength between the first molded body 901B and the second molded body 902B can be ensured.

(Seventh embodiment)
As a seventh embodiment, a method of forming a molded body 1900 molded based on the flowchart shown in FIG. 49 in the description of the resin molding method according to the sixth embodiment using the resin molding apparatus 1000B according to the fifth embodiment. explain.

In addition, the molding method of the molded body 1900 according to the present embodiment is a method based on the flowchart of the resin molding method of the molded body 900B according to the sixth embodiment shown in FIG. 49, and in the molded product single layer forming step (S201). The ultraviolet irradiation process (S212) as a liquid resin material curing process has a characteristic molding method. Accordingly, the same components as those in the resin molding method according to the sixth embodiment are denoted by the same reference numerals, and descriptions of common steps are omitted.

(Molded product single layer forming process)
In the resin molding method according to this embodiment, a molded body 1900 shown in the external perspective view of FIG. 69 is molded. As shown in FIG. 69, a molded body 1900 as the second molded body includes a first molded body 1901 having a cross-sectional shape of a first cross section 1901a molded by the resin material Mp1 as the first material, A container having an outer shape of a truncated cone having a cross-sectional shape 1900a having an inner space and a bottom formed by a second molded body 1902 having a cross-sectional shape of a second cross-section 1902a formed by the resin material Mp2 as a material of Is illustrated.

The resin molding method according to the present embodiment is illustrated by the same method as the molding method of the first first mold layer 810 and the first molding layer 910 in the resin molding method according to the sixth embodiment described above. A first mold layer 1810 and a first mold layer 1910 that are not formed are formed. Then, the first molding layer 1810 is used as a first molding single layer, the first molding layer 1910 is used as a first molding single layer, and the second molding method is transferred to the lamination step (S204). The molded product single layer forming step (S201) will be described.

(Molded product single layer forming process)
In the molded product single layer forming step (S201) related to the second layer transferred from the laminating step (S204), as shown in FIG. 70, the connection layer forming step (S2121) included in the ultraviolet irradiation step (S212) is performed. This is performed to form the connection layer 1820a, and then the upper layer formation step (S2122) is performed.

As shown in FIG. 70, in the connection layer forming step (S2121), the connection layer 1820a constituting the second mold layer 1820 as the second second mold product single layer is formed from the ultraviolet irradiation unit 500. It is formed by a first connection layer 1821a obtained by curing the liquid resin material Mf by irradiation with ultraviolet rays UV, a second connection layer 1822a, and a third connection layer 1823a constituting a boundary wall.

The upper layer forming step (S2122) is performed on the connection layer 1820a to form the upper layer 1820b. In the upper layer forming step (S2122), the first upper layer 1821b is stacked on the first connection layer 1821a, the second upper layer 1822b is stacked on the second connection layer 1822a, and the third upper layer 1823b is stacked on the third connection layer 1823a. The upper layer 1820b is formed by stacking.

FIG. 71 shows a partially enlarged view of part D shown in FIG. As shown in FIG. 71, in the second mold layer 1820 formed by executing the upper layer forming step (S2122), a region where the resin material Mp1 and the resin material Mp2 are injected and filled, a so-called cavity is formed. The That is, a molding region 1820s is configured by the space region between the first connection layer 1821a and the second connection layer 1822a and the space region between the first upper layer 1821b and the second upper layer 1822b. . The molding region 1820s is divided by a third connection layer 1823a that is a boundary wall and a third upper layer 1823b, and the first molding region 182As as the first cavity region and the second cavity region as the second cavity region. The second molding region 182Bs is formed. And it transfers to a single layer injection molding process (S202).

In the resin molding method according to the present embodiment, the third connection layer 1823a formed by executing the connection layer forming step (S2121), the third upper layer 1823b formed by executing the upper layer forming step (S2122), The boundary wall layer forming step for forming the boundary wall by the UV irradiation step (S2121) is included.

In the resin molding method according to the present embodiment, from the second layer to the last Nth layer, the same manufacturing method as the resin molding method according to the sixth embodiment described above is followed by the laminating step after the single-layer injection molding step (S202). (S204) is repeated, and as shown in FIG. 72, from the first mold layer 1810 constituted by the connection layer 1810a and the upper layer 1810b, the Nth constituted by the connection layer 18N0a and the upper layer 18N0b. A first molded body 1800 as a molded body in which N layers of molded product single layers up to the molding mold layer 18N0 are laminated, and the first molded body 1800 as a molding die, and a resin material Mp1 in an internal space, a so-called cavity. The resin material Mp2 is injected. Consists of a first molding layer 1910, a first molding layer 1921, and a second molding layer 1922 that are constituted by the first molding layer 1911 by the injected resin material Mp1 and the resin material Mp2. And a molded body 1900 as a second molded body laminated from the second molded layer 1920 to the Nth molded layer 19N0 composed of the Nth first molded layer 19N1.

As shown in FIG. 72, in the molded body 1900 according to the present embodiment, the first molded body 1901, the second molded body 1902, and third connection layers 1823a, 1833a,... , 18n3a and third upper layers 1823b, 1833b,..., 18n3b are stacked, but the third connection layers 1823a, 1833a,. The upper n-th layer is
n <N (n> 0 integer)
And

Thereby, in the mold release process (S205) described later, the mold 1900 is immersed in a solvent that selectively dissolves the ultraviolet curable resin constituting the first molded body 1800 using a chemical mold release means. When separating, since the third upper layer 18n3b of the uppermost n layer is not exposed from the surface of the molded body 1900, the third connection layers 1823a, 1833a,..., 18n3a as boundary walls left inside the molded body 1900; Elution of the laminate of the third upper layers 1823b, 1833b, ..., 18n3b can be prevented.

And if it determines with the molded object single layer transferred to the lamination | stacking number confirmation process (S203) and having been laminated | stacked to the predetermined | prescribed lamination | stacking number (N layer) (YES), 1st molded object 1800, 2nd The molded body 1900 as the molded body is taken out from the storage tank 300 and is transferred to the mold release step (S205). In the mold release step (S205), as in the resin molding method according to the sixth embodiment, the first molded body 1800 is separated by physical means or chemical means, and a molded body 1900 can be obtained.

A molded body 1900 obtained by the resin molding method according to the present embodiment includes a first molded body 1901, a second molded body 1902, and third connection layers 1823a, 1833a,. .., 18n3b are separated and molded by the laminated body of the third upper layers 1823b, 1833b,. Thereby, the resin material Mp1 as the first material forming the molded body 1900 and the resin material Mp2 as the second material are not high in affinity or adhesion performance, or the resin material Mp1, Even if there is a large difference in the glass transition point of Mp2, the third connection layers 1823a, 1833a,..., Which are boundary walls that are hardened by ultraviolet UV using, for example, an epoxy-based resin or the like on the liquid resin material Mf. , 18n3a and the third upper layer 1823b, 1833b,..., 18n3b serve as an adhesive wall (adhesive layer) between the resin material Mp1 and the resin material Mp2, and the two colors of the resin materials Mp1 and Mp2 The adhesion strength between the first molded body 1901 of the molded molded body 1900 and the second molded body 1902 can be ensured.

By using an epoxy-based resin for the boundary wall, even the resin materials Mp1 and Mp2 having a difference in the crow transition point from the boundary wall can be chemically bonded, and the epoxy-based resin has a functional group designed. Therefore, depending on the types of the resin materials Mp1 and Mp2, the structure can be designed so that high adhesion can be obtained.

In the above-described embodiment, acrylate radical polymerization and epoxy cation polymerization are exemplified as the ultraviolet curable resin, but it can be said that resins other than this resin material are incompatible with molding by ultraviolet curing. Examples of the thermoplastic resin material that can be applied to the second molded bodies 900, 900A, 900B, and 1900 that are products include, as a crystalline resin, Pe (polyethylene), PP (polypropylene), PA (polyamide), and POM (polyacetal). , PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), PEEK (polyether ether ketone), and the like. An example of the liquid crystalline resin is LCP (Liquid Crystal Polymer). Examples of the amorphous resin include PS (polystyrene), ABS, PMMA (acrylic), PC (polycarbonate), PPE (polyphenylene ether), and the like.

In the resin molding method according to the above embodiment, the resin material constituting the molded bodies 900, 900A, 900B, 1900 is not limited as long as it is a thermoplastic resin that can be injection molded. That is, in the conventional method for forming a three-dimensional resin molding using a resin that is cured by energy rays, a monomer that can contain a catalyst that generates radicals by energy rays, such as an acrylate radical polymerization resin and an epoxy. It is limited to cationic polymerization resin. However, the resin molding method according to the above embodiment is not suitable for curable resins using energy rays. For example, as a crystalline resin, Pe (polyethylene), PP (polypropylene), PA (polyamide), POM (polyacetal), PBT ( Polybutylene terephthalate), PPS (polyphenylene sulfide), PEEK (polyether ether ketone) and the like. An example of the liquid crystalline resin is LCP (Liquid Crystal Polymer). As the amorphous resin, PS (polystyrene), ABS, PMMA (acrylic), PC (polycarbonate), PPE (polyphenylene ether), or the like can be applied.

In the resin molding apparatuses 1000, 1000A, and 1000B described above, the ultraviolet irradiation unit 500 and the injection units 600, 601, and 602 are relatively three with respect to the molding unit 400 by a stage driving device (not shown) of the stage 200 provided in the base 100. Although the apparatus enables dimensional movement, the present invention is not limited to this. For example, the ultraviolet irradiation unit 500 and the emission units 600, 601, and 602 may be held by a robot arm and driven relatively three-dimensionally with respect to the molding unit 400.

DESCRIPTION OF SYMBOLS 100 ... Base, 200 ... Stage, 300 ... Reservoir, 400 ... Molding part, 500 ... Energy beam irradiation part (ultraviolet irradiation part), 600 ... Injection part, 700 ... Control unit, 1000 ... Resin molding apparatus.

Claims (18)

Stage,
A storage tank installed on the stage;
An energy ray irradiating unit for irradiating energy rays;
An injection part that plasticizes the first material, which is a synthetic resin, and injects it from an injection port;
The stage, and the energy beam irradiating unit and the emitting unit include a driving unit that enables relatively three-dimensional movement,
The storage tank includes a table that can be driven at least in the direction of gravity inside, and stores a liquid cured resin material containing an energy beam curable resin that is cured by the energy beam.
The resin molding apparatus characterized by the above-mentioned. The energy beam irradiated from the energy beam irradiation unit hardens the cured resin material to form a first molded product in a layer shape,
The first material injected from the injection portion is cured, and a second molded product is formed in a layer shape,
A first molded body in which the first molded product is laminated in the direction of gravity and a second molded body in which the second molded product is laminated in the direction of gravity are formed.
The resin molding apparatus according to claim 1. A cavity for forming the second molded body is formed in the first molded body, and the second molded body is injected and filled with the first material toward the cavity.
The resin molding apparatus according to claim 2. The injection unit includes a first injection unit that plasticizes the first material and injects it from an injection port, and a second injection unit that plasticizes a second material that is a synthetic resin and injects it from the injection port And at least comprising
The resin molding apparatus according to claim 1. The energy beam irradiated from the energy beam irradiation unit hardens the cured resin material to form a first molded product in a layer shape,
Either one or both of the first material injected from the first injection part and the second material injected from the second injection part are cured, and the second molded product is formed into a layer. Formed,
A first molded body in which the first molded product is laminated in the direction of gravity and a second molded body in which the second molded product is laminated in the direction of gravity are formed.
The resin molding apparatus according to claim 4. A cavity for forming the second molded body is formed in the first molded body, and at least one or both of the first material and the second material are formed in the second molded body. Injected into the tee and filled,
The resin molding apparatus according to claim 5. An insertion member supply section that supplies an insertion member formed of a material different from the first material to the second molded product;
The insertion member is formed integrally with the second molded body;
The resin molding apparatus according to claim 2. The resin molding apparatus according to claim 7, wherein the synthetic resin is a thermoplastic resin and the insertion member is a metal. The resin molding apparatus according to claim 1, wherein the energy ray is an ultraviolet ray. 2. The resin molding apparatus according to claim 1, wherein the synthetic resin is a thermoplastic resin. A liquid curable resin material containing an energy beam curable resin stored in a storage tank installed on the stage is irradiated with energy rays, and the energy beam curable resin is cured to form a single-layer mold product single layer. Mold molding single layer forming step,
Single-layer injection molding process in which the first material, which is a plasticized synthetic resin, is injected and filled from the injection part toward the molding region formed in the mold molded product single layer to form a molded product single layer When,
A mold molding lamination step of laminating the first mold molding monolayer formed by the mold molding monolayer formation step, and forming a second mold molding monolayer by the mold molding monolayer formation step; ,
A first product single layer formed by the single layer injection molding step, and a second product single layer formed by the single layer injection molding step.
The mold molding laminated step is repeated a predetermined number of times, and a mold molded body in which the mold molding single layer is laminated by a predetermined number of layers, and
Repeating the molding lamination step a predetermined number of times to form a molded body laminated in the molding region of the molded body,
The resin molding method characterized by the above-mentioned. The single-layer injection molding process
The first material is injected from the first injection portion, filled in the first cavity region constituting the cavity of the mold molded product single layer, and solidified to form the first molded product single layer. Single layer injection molding process;
A second material, which is a plasticized synthetic resin, is injected from the second injection portion, filled into a second cavity region that constitutes the cavity of the mold single layer, and solidified. The resin molding method according to claim 11, further comprising a second single-layer injection molding step of forming a layer. The mold product single layer forming step includes:
A boundary wall layer forming step of forming a boundary wall formed by curing the cured resin material at a boundary between the first cavity region and the second cavity region;
The resin molding method according to claim 12. The molded product lamination step includes an insertion member supply step of arranging an insertion member in the molded product single layer,
The insertion member is formed integrally with the molded body;
The resin molding method according to claim 11. Including a mold release step of releasing the molded body from the mold molded body,
The mold release step dissolves the molded body;
The resin molding method according to claim 11. The resin molding method according to claim 11, wherein the energy rays are ultraviolet rays. The resin molding method according to claim 11, wherein the synthetic resin is a thermoplastic resin. The resin molding method according to claim 14, wherein the insertion member is a metal.

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