1.377099 六、發明說明： 【發明所屬之技術領域】 本發明係有關於一種快速模具製造方法，特別是有關 於一種利用高塑性之複合材料的快速模具製程。 【先前技術】 一般傳統鈑金模具皆為鋼模，模具鋼胚經取料、粗加 工、應力釋除、線切割、放電、研磨加工、拋光到表面處 理等嚴格道次始得產出模具，開發時程相對較為冗長且造 價高昂，因此，新車測試或維修備品件等具有少量多樣之 零件產品，業界常選擇快速模具（又稱暫用模具或簡易模具) 取代永久性之鋼模。 一般快速模具因材料與製程之不同區分為低;fe點合金 或鋅合金、鑄鐵模具、樹脂模具、電鑄模具與金屬喷塗模 具..等。上述習知快速模具工法尚無法廣泛應用產業上，理 由約如下列所示：低熔點合金為鉛、鉍、錫等金屬組成之 合金，價格相對較昂貴且使用時需要加熱設備，鋅合金與 鑄鐵亦需要高溫熔解爐熔鍊成鑄胚，低熔點合金、鋅合金 與鑄鐵應用時皆須完成鑄胚，然後將鑄胚再加工出模面始 成模具；請參照圖1所繪示之先前.技術之樹脂模具剖視 圖。樹脂模具10為使用樹脂、硬化劑與填充物混合後灌注 而成形模仁，對於大型鈑金件之模具而言，全部應用樹脂 材料的成本非常高，造成模具成本降低有限。 因此，習知飯金沖壓快速模具（如低熔點合金或鋅合 3 金'鑄鐵模具、樹脂桓复 „ 相辦地較錢完全料Ϊ _錢模具..等） ^^之市場需求，實務應用上仍有許纽善的空間。 欲解決的問題係提供—種應崎造領域所使用 至^4成快速模具之大部分面積之主體部，再於砂模之 43=注成型-樹脂硬化層而形成複合材料快速 軸問題之技術手段係料-種複合 砂步驟包含:成型-砂模主體，該 〜t \ 表面’該第_表面造型練略對應於 樞侔1、％:造型；製作一樹脂模具框件’該樹脂模具 灌注一樹崎液於該樹脂模具框 钭ΠΓ!以於該第一表面上形成-樹脂混合材 次:合:=:合一於該砂模，形 本發明之特點係在於，本發明提供一種 ^模為主要成分之複合材料模具製程，樹脂#料可複^言 複雜表面品質佳模具表面’樹脂結構之内部 古、田： 強度鑄造用砂模材料’型砂價格低廉且經高溫繞結 I.37J099 佳，樹脂與砂模結合之複合材結構應用於大型複雜曲面產 品之簡易模具製造具有縮短時程、精度佳、品質好又經濟 的優勢。 【實施方式】 茲配合圖式將本發明較佳實施例詳細說明如下。 首先請參照圖2所繪示之本發明複合材料快速模具製 造方法實施例之流程圖以及圖3A至圖3E所繪示圖2之結 構剖面示意圖。本實施例中，其製造方法包含： (步驟S100)成型一砂模主體20，該砂模主體20具有 一第一表面22，較佳地，該第一表面22的造型係約略對 應於一工件原型30表面造型（如圖3A所示）。上述砂模主 體20係以一鑄砂混合水玻璃（Na2Si03)所組成之一矽砂水 玻璃混合物經燒結製程而製成。其應用之燒結製程係將該 矽砂水玻璃混合物導入一模箱中，並通入二氧化碳（C02) 氣體以形成濕態砂模（硬化成濕態砂模的時間隨模具大小 而有所不同，一般約5〜10分鐘，但不以此為限），再將濕 態砂模置入燒結爐中，以最高燒結溫度1050°C燒結至少2 小時為之。而上述矽砂水玻璃混合物之該鑄砂顆粒大小為 22 S至60 S，該水玻璃之重量比率為鑄砂之1 %至7 %。 (步驟S110)製作一樹脂模具框件40，該樹脂模具框件 40具有一容置空間4丨及一蓋板42,該容置空間41内具有 至少一定位支撐件43，該定位支撐件43可安裝於該容置 空間41之底面或側壁上（如圖3B所示）。 1.377099 (步驟S120)將該工件原型30設置於該定位支撐件43 上，且其欲提供複合材料快速模具60複製之工作面係朝上 (如圖3B所示）。 (步驟S130)組合並定位該砂模主體20於該樹脂模具框 件40中，並將該樹脂模具框件40閤上蓋板42，該砂模主 體20之該第一表面22與該工件原型30表面相對並保持一 間隙44，此間隙44即決定覆蓋於該第一表面22上的樹脂 材料的厚度。若覆蓋該砂模主體20不限於該第一表面22， 也欲包含該砂模主體20的其他表面，如側面或頂面，則須 在定位該砂模主體20於該樹脂模具框件40時，預留該砂 模主體20表面與該樹脂模具框件40容置空間41壁面之間 的距離（如圖3C所示）。 (步驟S140)灌注一樹脂混合液50於該樹脂模具框件 40之該容置空間41中，以於該第一表面22上形成一樹脂 混合材料層51。為使該樹脂混合液50在充填過程中不致 產生氣泡，本步驟在一抽真空製程中進行為佳。而該抽真 空製程，係可在該樹脂模具框件40之該容置空間41中配 置抽真空設備70，以使該樹脂模具框件40形成一真空箱 (如圖3D所示），該真空箱内之真空壓力係低於大氣壓力2 Kg/cm2以上時，始進行灌注該樹脂混合液50作業。上述 該樹脂混合液50係包含100%重量之樹脂與300%至500% 重量添加物混合後，再添加50%至100%重量之硬化劑而形 成。上述該重量添加物可為鐵粉、鋁粉、玻璃纖維、陶瓷 6 137.7099 t t 粉或其他強化結構之填入物。 (步驟S150)取出該樹脂混合液50硬化後結合於該砂模 主體所形成之該複合材料快速模具60(如圖3E所示），樹月旨 混合液50硬化的時間隨模具大小而有所不同，一般約為 5〜40分鐘，但不以此為限。 上述之工件原型30表面係為一鈑件零件的外表兩 時，其所製成之該複合材料快速模具60可為一動模模具咬 為一定模模具；而上述工件原型30表面為一鈑件零件的内 面時，其製成之該複合材料快速模具60亦可為一動模模足 或可為一定模模具。 另外，為利於該複合材料快速模具60成形後順利脱 模，在該工件原型30設置於樹脂模具框件内之定位支撑件 上的時候或之前’更包含一噴灑離型劑之步驟，以對該工 件原型30表面或樹脂模具框件40内表面進行嘴灑離型劑。 請參照圖4所繪示本發明複合材料快速模具埋設支撑 架體實施例之剖示圖。其為使該砂模主體20在燒結之後獲 得更佳的抗拉強度，係可在該矽砂水玻璃混合物中更埋設 至少一支撐架體21。當然’若製成之複合材料快速模具60 屬於大型模具時，所埋設之該支撐架體21之一端可向外突 伸，形成一固定栓211的固持結構，以利夾持搬運。 再請參照圖5所繪示本發明複合材料快速模具之表面 形成粗糙面實施例之剖示圖。本實施例中’該砂模主體2〇 與該樹脂混合材料層51之結合面具有至少一刻痕圖案之 7 U/./U99 粗S造型’以提高該樹脂混合材料層之結合強度。 請參照圖3E所示，本發明所提供之複合材料快速模具 把例’其複合材料快速模具6〇包括：-砂模主體2〇係 ' 一衣囟22 ;以及一樹脂混合材料層51係成型於 該第一表面99 I· ’該樹脂滿《合材料層51形成一工作表面 61°該樹脂混合#料層51係包含職重量之樹脂與麵 5〇〇%重量之添加物混合後，再添加5G%至1〇〇%重量之1.377099 VI. Description of the Invention: TECHNICAL FIELD OF THE INVENTION The present invention relates to a rapid mold manufacturing method, and more particularly to a rapid mold process for a composite material utilizing high plasticity. [Prior Art] Generally, the traditional sheet metal molds are steel molds, and the mold steel embryos are produced by the rigorous passes of material extraction, rough processing, stress release, wire cutting, discharge, grinding, polishing and surface treatment. The time course is relatively long and costly. Therefore, there are a small number of parts and components for new car testing or maintenance parts. The industry often chooses quick molds (also called temporary molds or simple molds) to replace permanent steel molds. Generally, fast molds are classified as low due to differences in materials and processes; fe-point alloys or zinc alloys, cast iron molds, resin molds, electroforming molds, and metal spray molds. The above-mentioned conventional rapid mold method cannot be widely applied in the industry for the following reasons: the low melting point alloy is an alloy composed of lead, bismuth, tin and the like, and the price is relatively expensive and requires heating equipment when used, zinc alloy and cast iron. It is also necessary to melt the melting furnace into a casting embryo. The low melting point alloy, the zinc alloy and the cast iron must be finished with the casting embryo, and then the casting embryo is reworked into the mold surface to form a mold; please refer to the previous figure shown in Fig. 1. A cross-sectional view of a technical resin mold. The resin mold 10 is formed by mixing a resin, a hardener, and a filler to form a mold core. For a mold of a large sheet metal part, the cost of applying the resin material is extremely high, resulting in a limited reduction in mold cost. Therefore, the conventional rice gold stamping rapid mold (such as low melting point alloy or zinc alloy 3 'cast iron mold, resin 桓 „ 相 相 较 较 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ There is still room for the new good. The problem to be solved is to provide the main part of the area of the mold that is used in the field of the Nagasaki, and then to the sand mold 43 = injection molding - resin hardening layer The technical means for forming the rapid axis problem of the composite material--the composite sand step comprises: forming-sand mold body, the ~t \ surface' the first surface styling is corresponding to the pivot 侔 1, %: styling; Resin mold frame member' The resin mold is filled with a yasaki liquid in the resin mold frame 以! to form a resin mixed material on the first surface: y: =: united in the sand mold, the characteristics of the present invention The invention provides a composite mold process with a mold as a main component, a resin #material can be used to reproduce a complex surface quality, a good mold surface, a resin structure, an ancient field, a field mold material for strength casting, and a low-cost sand mold. And after high temperature winding I.37J09 9 Excellent, composite structure of resin and sand mold is applied to simple mold manufacturing of large complex curved surface products, which has the advantages of shortening time history, good precision, good quality and economical. [Embodiment] The embodiment is described in detail below. First, please refer to the flowchart of the embodiment of the composite rapid mold manufacturing method of the present invention illustrated in FIG. 2 and the cross-sectional view of the structure of FIG. 2 illustrated in FIG. 3A to FIG. 3E. In this embodiment, The manufacturing method comprises: (Step S100) molding a sand mold body 20 having a first surface 22, preferably, the shape of the first surface 22 approximately corresponds to a surface shape of a workpiece prototype 30 (eg The sand mold body 20 is made by a sintering process of a sand-water glass mixture composed of a cast sand mixed water glass (Na2Si03). The sintering process is applied to the sand water glass. The mixture is introduced into a mold box and carbon dioxide (C02) gas is introduced to form a wet sand mold (the time to harden into a wet sand mold varies with the size of the mold, generally about 5 to 10 minutes, but Without limitation, the wet sand mold is placed in a sintering furnace and sintered at a maximum sintering temperature of 1050 ° C for at least 2 hours. The sand particle size of the above-mentioned enamel water glass mixture is 22 S to 60 S, the weight ratio of the water glass is 1% to 7% of the foundry sand. (Step S110) A resin mold frame member 40 is formed. The resin mold frame member 40 has an accommodating space 4A and a cover plate 42. The accommodating space 41 has at least one positioning support member 43. The positioning support member 43 can be mounted on the bottom surface or the side wall of the accommodating space 41 (as shown in FIG. 3B). 1.377099 (Step S120) The workpiece prototype 30 It is disposed on the positioning support member 43, and it is intended to provide the work surface of the composite quick mold 60 to be copied upward (as shown in FIG. 3B). (Step S130) Combining and positioning the sand mold body 20 in the resin mold frame member 40, and closing the resin mold frame member 40 to the cover plate 42, the first surface 22 of the sand mold body 20 and the workpiece prototype The surface of the 30 is opposed to and maintains a gap 44 which determines the thickness of the resin material overlying the first surface 22. If the cover body 20 is not limited to the first surface 22, and other surfaces of the sand mold body 20, such as the side or the top surface, are to be included, the sand mold body 20 must be positioned when the mold body 40 is positioned. The distance between the surface of the sand mold main body 20 and the wall surface of the resin mold frame member 40 accommodating space 41 is reserved (as shown in FIG. 3C). (Step S140) A resin mixed liquid 50 is poured into the accommodating space 41 of the resin mold frame member 40 to form a resin mixed material layer 51 on the first surface 22. In order to prevent the bubble mixture 50 from being bubbled during the filling process, this step is preferably carried out in an evacuation process. In the vacuuming process, the vacuuming device 70 is disposed in the accommodating space 41 of the resin mold frame member 40, so that the resin mold frame member 40 forms a vacuum box (as shown in FIG. 3D). When the vacuum pressure in the tank is lower than the atmospheric pressure of 2 Kg/cm2 or more, the operation of injecting the resin mixed liquid 50 is started. The above resin mixed solution 50 is formed by mixing 100% by weight of a resin with 300% to 500% by weight of an additive, and further adding 50% to 100% by weight of a hardener. The above weight additive may be iron powder, aluminum powder, glass fiber, ceramic 6 137.7099 t t powder or other reinforcing structure filling. (Step S150) taking out the composite rapid mold 60 (shown in FIG. 3E) formed by bonding the resin mixed solution 50 to the sand mold body, and the time for the hardening of the mixed liquid 50 is different depending on the size of the mold. Different, generally about 5 to 40 minutes, but not limited to this. When the surface of the workpiece prototype 30 is the appearance of a component part, the composite rapid mold 60 can be a movable mold biting into a certain mold; and the surface of the workpiece prototype 30 is a component part. The composite rapid mold 60 made of the inner surface may also be a movable mold foot or may be a mold mold. In addition, in order to facilitate the smooth demolding of the composite rapid mold 60 after forming, when the workpiece prototype 30 is disposed on the positioning support in the resin mold frame, or before, the step of spraying the release agent is further included. The surface of the workpiece prototype 30 or the inner surface of the resin mold frame member 40 is subjected to a nozzle release agent. Referring to Figure 4, a cross-sectional view of an embodiment of the composite rapid mold embedding support frame of the present invention is illustrated. In order to obtain a better tensile strength of the sand mold body 20 after sintering, at least one support frame 21 may be further embedded in the sand water glass mixture. Of course, if the composite quick mold 60 is a large mold, one end of the embedded support body 21 can be protruded outward to form a holding structure of the fixing bolt 211 for gripping and carrying. Referring again to Figure 5, a cross-sectional view of an embodiment of a rough surface of a composite rapid mold of the present invention is illustrated. In the present embodiment, the bonding surface of the sand mold main body 2 and the resin mixed material layer 51 has at least one notched pattern of 7 U/./U99 coarse S shape 'to improve the bonding strength of the resin mixed material layer. Referring to FIG. 3E, the composite rapid mold of the present invention provides a composite rapid mold 6 including: - a sand mold body 2 ' a 囟 22; and a resin mixed material layer 51 The first surface 99 I· 'the resin full material layer 51 forms a working surface 61°. The resin mixture # material layer 51 is a mixture of the resin containing the working weight and the surface 〇〇% by weight of the additive, and then Add 5G% to 1% by weight
殖她劑而$成’其中，該重量添加物可為鐵粉、銘粉、玻 璃纖維或陶_II 、 等可強化結構之添加物。該複合材料快速 riZZi—動模或—定模，其巾該砂模主體2G與該樹 曰混。材料層51之結合面具有至少-刻痕圖案之粗糙面s 造型’以提高該樹胞混合材料層51之結合強:之= 混合材料層51f4话 放厌且a樹月曰 的其他表i 覆於該砂模主體20該第—表面22之外 材料種新式的樹脂與砂模為主要成分之複合 品質佳之程，樹脂材料可複製複雜度高且表面 品之快複合材結構應用於大型複雜曲面產 的優勢。本有縮短軸、精餘、品質好又經濟 鈑金模具之少適用於新車開發或維修備品件之大型 快速模呈4應用上，本發明之製程可取代現有 ml 、達到快速、經濟、有效率之開發目標。特 、、用於汽車大型鈑金件開發與試製，節省模具費用 8 1,377099 » * 6〇/❶以上，縮短開發時程50%以上。與傳統樹脂模具比較 約可節省80%以上之樹脂材料成本。樹脂表面層複製性佳 且表面品質好，成形速度快。與辞合金、低熔點合金與鑄 鐵杈具比較，不需加熱溶解設備且不必後加工成形模面， 具有施工簡易且時程縮短等優勢。應用耐高溫之多孔性砂 模與樹脂結合成形性佳，對於大型鈑金件模具具有吸震效 果，模具壽命較一般全樹脂模具長且價格低廉。且本發明 應用範圍廣泛，幾乎可同時應用於汽車、航太、醫療與工 具機等產業，產品上可應用於塑膠模具與射蠟模具等場合。 综上所述，乃僅記載本發明為呈現解決問題所採用的 技術手#又之實施方式或實施例而已，並非用來限定本發明 專利實施之範圍。即凡與本發明專利申請範圍文義相符， 或依本發明專利範圍所做的均等變化與修飾，皆為本發明 專利範圍所涵蓋。 【圖式簡單說明】 圖1繪示先前技術之樹脂模具剖視圖； 圖2繪示本發明複合材料快速模具製造方法實施例之流 程圖； 圖3A至圖3E繪示圖2之結構剖面示意圖； 圖4㈣本㈣複合材料快速模具埋言免支揮架體實施例 之剖示圖；以及 圖5繪示本發明複合材料快速模具之表面形成粗縫面實 施例之剖示圖。 【主要元件符號說明】 9 1.377099The addition agent may be an additive of a reinforced structure such as iron powder, powder, glass fiber or ceramic _II. The composite material is fast riZZi-moving mold or mold-fixing, and the sand mold body 2G is mixed with the tree. The bonding surface of the material layer 51 has a rough surface s shape of at least a scribe pattern to improve the bonding strength of the tree mixed material layer 51: the mixed material layer 51f4 is disgusting and the other table i of the tree is covered The new type of resin and the sand mold are the main components of the sand mold main body 20, and the resin material can be copied to a large complex surface. The advantage of production. The invention has the advantages of shortening the shaft, fineness, good quality and economical sheet metal mold, and is suitable for the large-scale rapid mold application of the new vehicle development or maintenance of the spare parts. The process of the invention can replace the existing ml, and achieve fast, economical and efficient. Development goals. Specially used for the development and trial production of large sheet metal parts for automobiles, saving mold costs 8 1,377099 » * 6〇/❶ or more, shortening the development time by more than 50%. Compared with traditional resin molds, it can save more than 80% of the cost of resin materials. The resin surface layer has good reproducibility and good surface quality, and the forming speed is fast. Compared with the alloy, the low melting point alloy and the cast iron cookware, there is no need to heat the dissolving equipment and it is not necessary to post-form the mold surface, which has the advantages of simple construction and shortened time course. The application of the high-temperature resistant porous sand mold and the resin is excellent in formability, and has a shock absorbing effect on the large-scale sheet metal mold, and the mold life is longer than that of the general all-resin mold and the price is low. The invention has wide application range and can be applied to industries such as automobile, aerospace, medical and tooling machines at the same time, and can be applied to plastic molds and wax molds. In summary, it is merely described that the present invention is intended to provide a solution to the problem, and is not intended to limit the scope of the practice of the present invention. That is, the equivalent changes and modifications made in accordance with the scope of the patent application of the present invention or the scope of the invention are covered by the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view showing a prior art resin mold; FIG. 2 is a flow chart showing an embodiment of a composite rapid mold manufacturing method according to the present invention; and FIGS. 3A to 3E are cross-sectional views showing the structure of FIG. 4(4) A cross-sectional view of the embodiment of the (4) composite material rapid mold embedding free-spike body; and FIG. 5 is a cross-sectional view showing an embodiment of the surface of the composite rapid mold of the present invention. [Main component symbol description] 9 1.377099
ίο 20 21 211 22 30 40 41 42 43 44 50 51 60 61 70 S 樹脂材料模具 砂模主體 支撐架體 固定栓 第一表面 工件原型 樹脂模具框件 容置空間 蓋板 定位支樓件 間隙 樹脂混合液 樹脂混合材料層 複合材料快速模具 工作表面 抽真空設備 粗糙面ο 20 20 21 211 22 30 40 41 42 43 44 50 51 60 61 70 S Resin material mold sand mold main body support frame body fixing bolt first surface workpiece prototype resin mold frame accommodating space cover positioning fulcrum gap resin mixture Resin mixed material layer composite material rapid mold working surface vacuuming equipment rough surface