JPH0581679B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Application Field] The present invention relates to a method for manufacturing a porous electroformed body,
More specifically, for example, it is a method for manufacturing a porous electroformed body for molding a skin body, which is an interior part of an automobile, by a vacuum forming method, and the conductive layer formed on the surface of the model can be eluted with an organic solvent. When welding the particles, by selecting the type and diameter of the particles in accordance with the organic solvent, the diameter of the vent hole of the electroformed body obtained by eluting the particles after the electroforming process is completed can be set to a desired value. The present invention relates to a method of manufacturing a porous electroformed body that allows adjustment. [Background of the Invention] Generally, a console box or the like which is an interior part of an automobile has an uneven skin pattern formed on its outer surface. In this case, the skin body of the console box etc. is usually made of a sheet of synthetic resin such as polyvinyl chloride, and is made of a so-called porous electroformed body having a plurality of ventilation holes. Molded using a molding method. Incidentally, various methods have been conventionally employed to manufacture porous electroformed bodies used in this type of vacuum forming method. For example, after forming a conductive layer on the surface of a model with a skin pattern, electroforming is performed to obtain an electroformed shell from the deposited metal, and the electroformed shell is peeled off from the conductive layer and then drilled or laser processed. A method of manufacturing a porous electroformed body by applying is known. However, with the above-mentioned conventional technology, if laser processing is attempted, the entire equipment will be quite expensive, and it will take a considerable amount of time, especially when forming a large number of ventilation holes, resulting in extremely low productivity. It has been pointed out that there are inconveniences that could lead to bad things. Also,
Drill processing has the disadvantage that it is not possible to obtain ventilation holes with a minute diameter because there is a limit to the diameter of the drill, and furthermore, similar to the laser processing described above, a large number of man-hours are required to obtain a large number of ventilation holes. is exposed. On the other hand, as disclosed in JP-A No. 60-152692, a spray layer containing an insulating material such as vinyl chloride lacquer solution mixed into a conductive coating is formed on the surface of the model. There is a method of obtaining a porous electroformed body by performing electrolytic treatment in an electrolytic solution. However, according to the above-mentioned method, it is not possible to selectively form vent holes in desired portions of the electroformed body. Therefore, when the electroformed body has a complicated shape, it becomes difficult to effectively adhere the resin sheet to the electroformed body using the vacuum forming method, and there is a possibility that molding defects may occur. Moreover, there is a problem in that a special electrolyte must be prepared. Furthermore, there is a method in which a silver layer is formed on the surface of the model by a silver mirror reaction, a silver corrosive is applied to areas of the silver layer that require ventilation holes, and then an electroforming process is performed to obtain a porous electroformed body. is disclosed in Japanese Patent Application Laid-Open No. 61-253392. However, in this method, it is necessary to perform a sealing treatment on the areas of the silver layer where vent holes are not required, and to apply a silver etching agent to the areas where the vent holes are required. As a result, the entire manufacturing process of the electroformed body becomes complicated, resulting in the drawback that it is difficult to efficiently manufacture the electroformed body. Moreover, since a silver corrosive agent is used, it is not possible to specify the location where the vent holes are formed, and it is impossible to arbitrarily select the diameter of the vent holes. Therefore, the present applicant first forms a conductive layer on the surface of the model, adheres a layer of particles to the surface of the conductive layer, performs an electroforming process to obtain an electroformed shell, and further dissolves the particles. proposed a method of manufacturing a porous electroformed body having a plurality of vent holes (Japanese Patent Application Laid-Open No. 163290/1989). According to this method, an effect can be obtained in that an electroformed body having countless minute ventilation holes can be manufactured easily and efficiently using extremely simple means. [Object of the Invention] The present invention has been made regarding a method for manufacturing this type of electroformed body, which involves performing silver plating on the surface of a model to form a conductive layer, and laminating the conductive layer to form a silver plate. By providing an inert organic solvent layer on the conductive layer and eluting particles whose type and diameter are selected according to the type of organic solvent with the organic solvent, the welding state of the particles to the conductive layer can be adjusted in various ways. Therefore, the diameter of the vent including the opening defined in the surface of the electroformed body is selected to a predetermined value to ensure sufficient strength of the electroformed body and to provide a skin body with excellent quality. An object of the present invention is to provide a method for manufacturing a porous electroformed body that makes it possible to form a porous electroformed body. [Means for achieving the object] In order to achieve the above object, the present invention provides the following steps: forming a conductive layer on the surface of a model; and using an organic solvent that is volatile and inert to the conductive layer. selecting the selected organic solvent on the conductive layer to obtain an organic solvent layer; selecting the type and diameter of particles that can be eluted in the selected organic solvent; a step of disposing particles on the surface of the organic solvent layer and melting a part of the particles to weld them to the conductive layer; a step of evaporating and removing the organic solvent layer; and a step of subjecting the model to an electroforming treatment to form the particles. forming an electroformed shell with a layer thinner than the diameter of the particles; separating the electroformed shell from the model; eluting the particles from the electroformed shell with an organic solvent; and dissolving the particles with the selected organic solvent. The method is characterized by comprising the steps of: obtaining an electroformed body having a plurality of desired vent opening diameters based on a combination of type and diameter. Further, after forming a first electroformed shell on the conductive layer formed on the surface of the model, second particles are applied to the first particles exposed to the outside from the first electroformed shell through an organic solvent. a step of electroforming the model to integrally form a second electroformed shell with a layer thinner than the diameter of the second particles on the first electroformed shell; The electroformed shell consisting of first and second electroformed shells is separated from the model, and the first and second particles are eluted from the electroformed shell with an organic solvent to form a plurality of desired vent openings. It is preferable to have a step of obtaining an electroformed body having the following. [Embodiments] Next, preferred embodiments of the method for producing a porous electroformed body according to the present invention in relation to an apparatus for carrying out the method will be listed and explained in detail below with reference to the accompanying drawings. . In FIG. 1, reference numeral 10 schematically indicates a porous electroformed body manufactured by the method of the present invention.
The electroformed body 10 has a thin plate shape, is molded into a predetermined shape, and has a skin surface 12 with an uneven pattern, etc.
is formed. A plurality of ventilation holes 14 are provided in the electroformed body 10.
are provided, and each vent hole 14 is located on the skin surface 1.
The opening 16 opens to the outside from the second side, and the opening 18 opens to the outside from the back side corresponding to the skin surface 12. Next, a model 20 used in the manufacturing process of the electroformed body 10 is shown in FIGS. 2a to 2d. Said model 2
0 corresponds to the shape of a desired skin body, and a skin pattern is formed on this top surface portion 22. On the other hand, in FIG. 2d, reference numeral 24 indicates an electroforming tank. The electroforming tank 24 is filled with an electrolytic solution 26, and the model 20 is immersed in this electrolytic solution 26. In this case, the top side of the model 20 has a power supply 2.
Electrodes 32a to 32c connected to the positive electrode of the model 20 through conductive wires 30a to 30c are arranged close to each other, and a conductive layer formed on this model 20 as described later is connected to the power supply 28 through a conductive wire 34. Connected to negative pole. The apparatus for carrying out the method for manufacturing a porous electroformed body according to the present invention is basically constructed as described above, and its operation and effects will be explained next. First, in the method of the present invention, polystyrene particles or acrylic particles are used as particles. When using the polystyrene particles, methyl ethyl ketone, ethylene dichloride, toluene, ethylene tetrachloride, and xylene are used as organic solvents that are inert and volatile to the conductive layer (silver plating layer). be done. On the other hand, when using acrylic particles, it is desirable to use methylene chloride or ethylene dichloride as the organic solvent. Therefore, as shown in FIG.
form 6. Next, an organic solvent is applied to the surface of the conductive layer 36 to form a solvent layer 38 having a predetermined thickness, and a plurality of particles 40 such as polystyrene are arranged at desired positions of the solvent layer 38. (See Figure 2b). Thereby, the solvent layer 3 of each particle 40
The part immersed in 8 is melted. And the second
As shown in Figure c, the solvent is evaporated to form a solvent layer 38.
When the particles 40 are removed, a plurality of particles 40 are left on the conductive layer 36.
are welded in a predetermined arrangement state. The welded state of the particles 40 is shown enlarged in FIG. At that time, since the welding state between the conductive layer 36 and the particles 40 can be easily confirmed, it is possible to confirm in advance the position of the vent hole 14 of the electroformed body 10 manufactured by the electroforming process described later. Become. In this way, the conductive layer 3 is placed on the upper surface 22 of the model 20.
6 and particles 40, the model 20 is immersed in the electrolytic solution 26 of the electroforming tank 24, as shown in FIG. 2d. Further, a conductive wire 34 connected to the negative terminal of the power source 28 is connected to the conductive layer 36, and this power source 28 is connected to the conductive layer 36.
Electrodes 32a to 32c connected to the positive electrode of No. 8 via conductive wires 30a to 30c are arranged in the electrolytic solution 26 corresponding to the shape of the upper surface 22 of the model 20,
The model 20 is subjected to electroforming treatment. Therefore, a metal such as nickel in the electrolytic solution 26 is precipitated, and this metal is laminated on the surface of the conductive layer 36 so as to fill the gaps between the particles 40, thereby forming an electroformed shell 42. In that case, as understood from Figure 2 d,
The electroformed shell 42 is selected to be thinner than the diameter of the particle 40, and the end of the particle 40 is connected to the electroformed shell 4.
2 is exposed into the electrolytic solution 26 from the surface thereof. Next, the model 20 is taken out from the electroforming tank 24,
After the electroformed shell 42 is peeled off from the model 20 together with the particles 40, the electroformed shell 42 is immersed in a solvent similar to the solvent used to form the solvent layer 38. As a result, the particles 40 are eluted and removed from the electroformed shell 42, and an electroformed body 10 having predetermined ventilation holes 14 is manufactured (see FIG. 1). In this case, according to the present embodiment, by selecting the type of organic solvent and the type of particles 40 constituting the solvent layer 38 and the diameter of the particles 40, it is possible to specifically define the surface layer of the electroformed body 10. opening 16
The diameter can be adjusted to a desired value. That is, when the state of FIG. 2c is enlarged and shown in FIG. 3, the portion of the particle 40 immersed in the solvent layer 38 is melted to form a welded portion 41 to the conductive layer 36. This welded portion 41 is then eluted and removed after the electroforming process, and finally defines the opening 16 in the electroformed body 10. Therefore, it is understood that if the shape of the welding part 41 can be selected, the diameter of the opening 16 defined in the electroformed body 10 can be adjusted to a desired value. Therefore, the present applicant uses a mixed solution of xylene and ethanol as an organic solvent, employs polystyrene particles as particles, and changes the concentration of xylene with respect to ethanol and the diameter of the polystyrene particles 40 to obtain a welding bond. Part 4
1, that is, a change in the diameter of the opening 16 was experimentally detected. This is shown in FIG. 4 and Tables 1 and 2.

【table】

[Table] Therefore, for example, in Table 2, a mixed solution of 20% xylene and 80% ethanol is used as the organic solvent, and 40 particles of polystyrene with a diameter of 443 μm are prepared.
If this is used, an opening 16 having a diameter of 106 μm will be defined in the electroformed body 10. It should be noted that it will be easily understood that if a similar experiment is conducted, a correlation between the type of organic solvent and the diameter of the opening 16 with respect to the acrylic particle size can be obtained. In addition, when selecting other various organic solvents, the type and diameter of particles that can be eluted in the selected organic solvent are selected, and similar experiments are performed to obtain the desired diameter of the opening 16. Just set the combination. In this way, by selecting the type and diameter of the particles 40 in accordance with the type and concentration of the organic solvent,
An electroformed body 10 provided with an opening 16 having a desired diameter can be obtained. This makes it possible to manufacture the electroformed body 10 with high precision, and has the effect that a skin body with excellent quality can be molded through this electroformed body 10. Moreover, the particles 40 can be welded to the conductive layer 36 while being separated from each other, and it is possible to prevent the inconvenience that, for example, the particles 40 are in closer contact with each other than necessary, resulting in insufficient strength of the electroformed body 10. It becomes possible. By the way, as shown in FIG. 5, the vent hole 14a is thicker and has a more complicated shape than the electroformed body 10.
The electroformed body 10a having the above can be easily manufactured by repeating the steps described above. That is, electroforming treatment is performed according to FIG. 2d,
After the electroformed shell 42 has been formed on the conductive layer 36, the model 20 is taken out from the electroforming tank 24 and is shown in FIG. 6a. Therefore, a solvent layer 38a is applied again to a predetermined thickness on the surface of the electroformed shell 42, and particles 40a are arranged on the solvent layer 38a (see FIG. 6b). Therefore, the particles 40a are in the solvent layer 38a.
The part immersed in the electroformed shell 42 is melted and the electroformed shell 42
The end portion of the particle 40 is welded to the exposed particle 40. Next, after removing the solvent layer 38a by evaporating the solvent, the model 20 is immersed in the electroforming tank 24 and subjected to electroforming treatment, thereby forming an electroformed shell 42a having a desired wall thickness. (See Figure 6c). Further, the model 20 is taken out from the electroforming tank 24, the electroformed shell 42a is peeled off from the model 20, and the particles 40a and 40 are immersed in a solvent.
is eluted and removed, and an electroformed body 10a having a complicatedly shaped vent hole 14a is obtained (see FIG. 5). [Effects of the Invention] As described above, according to the present invention, when a conductive layer is formed on the surface of a model and particles are welded to this conductive layer via an organic solvent, the particles are The welding state of the particles is adjusted by selecting the type and diameter, and then, after electroforming treatment, the particles are eluted and removed to produce an electroformed body having a plurality of ventilation holes. Therefore, by selecting the positions of the particles, it is possible to easily and reliably form a predetermined number of ventilation holes in desired parts of the electroformed body, and to ensure sufficient strength of the electroformed body itself. The advantage is that it can be done. Furthermore, by simply selecting the type and size of the particles in accordance with the organic solvent, it is possible to adjust the diameter of the opening on the skin surface side of the electroformed body to a desired size. As a result, a highly accurate electroformed body having predetermined ventilation holes can be obtained, and a skin body of excellent quality can be formed. Although the present invention has been described above with reference to preferred embodiments, the present invention is not limited to these embodiments, and various improvements and changes in design are possible without departing from the gist of the present invention. Of course.

[Brief explanation of the drawing]

FIG. 1 is a schematic vertical cross-sectional view of an electroformed body manufactured by the manufacturing method according to the present invention, FIGS. A partially enlarged view showing the state in which particles are welded to the conductive layer during the process. Figure 4 shows the relationship between the change in the diameter of the opening of the electroformed body obtained by selecting the concentration of the organic solvent and the size of the particles. 5 are partial vertical sectional views of other electroformed bodies, and FIGS. 6a to 6c are schematic explanatory diagrams showing a method of manufacturing the electroformed body shown in FIG. 4. 10... Electroformed body, 12... Skin surface, 14... Vent hole,
16, 18...Opening part, 20...Model, 22...Upper surface part, 24...Electroforming tank, 40...Particles, 42...Electroforming shell.

Claims (1)

[Claims] 1. A step of forming a conductive layer on the surface of the model, selecting a type of organic solvent that is volatile and inert to the conductive layer, and applying the selected organic solvent on the conductive layer. a step of selecting the type and diameter of particles that can be eluted in the selected organic solvent, and disposing the selected particles on the surface of the organic solvent layer to obtain one of the particles. a step of evaporating and removing the organic solvent layer; and a step of electroforming the model to form an electroformed shell having a layer thinner than the diameter of the particles. , separating the electroformed shell from the model and eluting the particles from the electroformed shell with an organic solvent to open a plurality of desired vent holes based on the combination of the selected organic solvent and particle type and diameter; A method for manufacturing a porous electroformed body, comprising: obtaining an electroformed body having a diameter. 2. The method according to claim 1, after forming a first electroformed shell on the conductive layer formed on the surface of the model, an organic solvent is applied to the first particles exposed to the outside from the first electroformed shell. a step of welding second particles through the model; and electroforming the model to integrally form a second electroformed shell with a layer thinner than the diameter of the second particles on the first electroformed shell. separating the electroformed shell consisting of the first and second electroformed shells from the model, and eluting the first and second particles from the electroformed shell with an organic solvent to form a plurality of particles. A method for producing a porous electroformed body, comprising: obtaining an electroformed body having a desired vent opening diameter of .