Method for manufacturing core product, method for removing residual resin, and device for removing residual resin

Abstract

Provided are a method for manufacturing a core product, a method for removing residual resin, and an apparatus for removing residual resin, comprising: supplying molten resin; placing a conveying jig on a collecting unit by conveying the conveying jig together with a core body from a resin supply device to a collecting unit; separating resin solidified in a resin forming area from resin solidified in a resin flow path by removing the core body from the conveying jig; forming residual resin, which is a residue of the solidified resin in the resin flow path, and obtaining a core product, which includes the core body and the solidified resin formed in the resin forming area; and causing the residual resin to drop from the resin flow path into the collecting unit by causing an extrusion unit to abut against the residual resin from above.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a core product, a method for removing residual resin, and an apparatus for removing residual resin. Background Art

[0002] Patent document JP2015-023597A discloses a resin filling device, which includes: a lower mold having a plunger that pressurizes the resin by extruding the resin upward; a resin injection mold arranged above the lower mold, which is able to slide up and down and has an injection port facing the lower end surface of the laminated iron core for injecting resin into the magnet insertion hole of the laminated iron core; and a pin that drops unnecessary material in the injection port downward after the laminated iron core is removed from the resin injection mold after the magnet insertion hole is filled with resin. Therefore, in the resin filling device of patent document JP2015-023597A, the resin injection mold does not move horizontally toward other devices, etc. In other words, the removal of unnecessary material from the injection port of the resin injection mold is completed in the resin filling device. Summary of the Invention

[0003] Typically, the process of filling the magnet socket with resin in the resin filling device takes a relatively long time. Therefore, as disclosed in patent document JP2015-023597A, when there is a process other than resin filling (such as removing unnecessary substances), there is a concern that this may affect the production efficiency of the core product. Therefore, in order to improve the production efficiency of the core product, in the manufacturing process of the core product, there is a situation where the intermediate of the core product passes through various devices. In this case, in order to make it easy to transport the intermediate, there is a situation where the intermediate is transported between these devices while being placed on a transport fixture.

[0004] The transfer jig includes a resin flow path located at a position corresponding to a resin forming region of the intermediate. While resin is being formed in the resin forming region of the intermediate, molten resin is injected from the lower mold into the resin forming region through the resin flow path while the transfer jig, which holds the intermediate, is further placed on the lower mold. Afterwards, the intermediate, after resin formation, is removed from the transfer jig and transferred to the next process. The transfer jig is then returned to a placement device for placing the intermediate, before resin formation, on the transfer jig.

[0005] When the intermediate body after resin formation is removed from the transport jig, solidified resin remains in the resin flow path of the transport jig. Therefore, there is a concern that the residual resin in the resin flow path may drip from the transport jig and spread around due to vibrations generated in the transport jig when the intermediate body is removed from the transport jig, vibrations generated in the transport jig when the transport jig is returned to the placement device, and the like.

[0006] Therefore, the present disclosure describes a method for manufacturing a core product, a method for removing residual resin, and an apparatus for removing residual resin, which are capable of preventing residual resin that has fallen from a transfer jig from scattering around.

[0007] According to one aspect of the present disclosure, a method for manufacturing a core product includes: in a state where a core body is placed on a conveying fixture so that a resin forming area provided in the core body is communicatively connected to a resin flow path of the conveying fixture, supplying molten resin to the resin forming area via the resin flow path using a resin supply device; after supplying the molten resin, placing the conveying fixture on the collection unit by conveying the conveying fixture together with the core body from the resin supply device; after placing the conveying fixture in the collection unit, separating the resin solidified in the resin forming area from the resin solidified in the resin flow path by removing the core body from the conveying fixture; forming residual resin by the separation and obtaining the core product, wherein the residual resin is the residue of the solidified resin in the resin flow path, and the core product includes the core body and the solidified resin formed in the resin forming area; and after forming the residual resin, causing the residual resin to fall from the resin flow path into the collection unit by causing an extrusion unit to abut against the residual resin from above.

[0008] According to another aspect of the present disclosure, a method for removing residual resin includes: placing the conveying jig on the collection unit by conveying the conveying jig together with the core body to a collection unit in a state where the core body is placed on a conveying jig so that a resin forming area provided in the core body is communicatively connected to a resin flow path of the conveying jig, the core body and the conveying jig having solidified resin integrally formed in the resin forming area and in the resin flow path; after placing the conveying jig in the collection unit, separating the resin solidified in the resin forming area from the resin solidified in the resin flow path by removing the core body from the conveying jig, forming residual resin by the separation, the residual resin being the residue of the solidified resin in the resin flow path; after forming the residual resin, dropping the residual resin from the resin flow path to the collection unit by causing the extrusion unit to abut against the residual resin from above.

[0009] According to another aspect of the present invention, a device for removing residual resin includes: a conveying unit, which is configured to convey a conveying fixture with a core body placed thereon, the core body having a resin forming area, and the conveying fixture having a resin flow path, which is communicatively connected to the resin forming area when the core body is placed on the conveying fixture; a collecting unit, which is configured to place the conveying fixture thereon; a separating unit, which is configured to separate the conveying fixture placed on the collecting unit and the core body placed on the conveying fixture from each other; and an extrusion unit, which is configured to extrude the residual resin downward to the collecting unit, the residual resin remaining in the resin flow path of the conveying fixture after the core body is removed by the separating unit.

[0010] According to the method for manufacturing a core product, the method for removing residual resin, and the apparatus for removing residual resin of the present disclosure, it is possible to prevent residual resin that has fallen from a conveying jig from scattering around. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a perspective view showing an example of a rotor laminated core.

[0012] Figure 2 : is a schematic diagram showing an example of a manufacturing apparatus for a rotor laminated core.

[0013] Figure 3 is a cross-sectional view schematically showing an example of a resin supply device.

[0014] Figure 4 is a side view schematically showing an example of an apparatus for removing residual resin.

[0015] Figure 5 It is along Figure 4 Cross-sectional view taken along line VV.

[0016] Figure 6 is a top view schematically showing an example of a collecting unit.

[0017] Figure 7 is a front view showing an example of the second stopper.

[0018] Figure 8 It is a view for describing an example of a process of removing the residual resin.

[0019] Figure 9 is used to describe Figure 8 The view of the instance to be processed later.

[0020] Figure 10 is used to describe Figure 9 The view of the instance to be processed later.

[0021] Figure 11 is used to describe Figure 10 The view of the instance to be processed later.

[0022] Figure 12 It shows Figure 11 An enlarged view of the rotor laminated core and transfer fixture.

[0023] Figure 13 is used to describe Figure 11 The view of the instance to be processed later.

[0024] Figure 14 is used to describe Figure 11 The view of the instance to be processed later.

[0025] Figure 15 Is used to describe Figure 13 and 14 The view of the instance to be processed later.

[0026] Figure 16 is used to describe Figure 15 The view of the instance to be processed later.

[0027] Figure 17 is used to describe Figure 16 The view of the instance to be processed later.

[0028] Figure 18 is used to describe Figure 17 The view of the instance to be processed later.

[0029] Figure 19 is a flowchart for describing an example of a method for removing residual resin. DETAILED DESCRIPTION

[0030] In the following description, the same elements or elements having the same functions will be given the same reference numerals, and repeated descriptions thereof will be omitted.

[0031] [Laminated rotor core]

[0032] First, refer to Figure 1 The configuration of the rotor laminated core 1 (core product) will be described. The rotor laminated core 1 includes a laminated body 2 (core body), a plurality of permanent magnets 3, and a plurality of cured resins 4.

[0033] The stacked body 2 has a columnar shape. An axial hole 2a is provided in the center of the stacked body 2, extending along a central axis Ax. The axial hole 2a extends in the height direction (vertical direction) of the stacked body 2. Since the stacked body 2 rotates around the central axis Ax, the central axis Ax also serves as the axis of rotation. A shaft is inserted into the axial hole 2a.

[0034] A plurality of magnet insertion holes (resin forming areas) 5 are formed in the laminate 2. Figure 1 As shown, the magnet insertion holes 5 can be arranged at predetermined intervals along the outer peripheral edge of the laminate 2. Each magnet insertion hole 5 penetrates the laminate 2 to extend along the central axis Ax (height direction). One permanent magnet 3 can be inserted into one magnet insertion hole 5, or multiple permanent magnets 3 can be inserted into one magnet insertion hole 5.

[0035] The laminate 2 is formed by stacking a plurality of blanking parts W. The blanking parts W are plate-shaped bodies in which a metal plate (e.g., an electromagnetic steel plate) is blanked into a predetermined shape and have a shape corresponding to the laminate 2. The blanking parts W adjacent to each other in the height direction can be fastened to each other by the stacking riveting unit 6 (see Figure 1 ), can be joined by adhesive, or can be joined by welding. The stacked body 2 can be constructed by so-called rotational lamination or skew motion.

[0036] The solidified resin 4 is a solidified product of a molten resin material (molten resin) filled in the magnet insertion hole 5 in which the permanent magnet 3 is provided. The solidified resin 4 can be configured to fix the permanent magnet 3 in the magnet insertion hole 5. The solidified resin 4 can be configured to join the punched parts W adjacent to each other in the height direction (stacking direction).

[0037] [Rotor laminated core manufacturing equipment]

[0038] Next, we will refer to Figure 2 The manufacturing apparatus 100 of the rotor laminated core 1 is described. The manufacturing apparatus 100 is configured to manufacture the rotor laminated core 1 from a strip-shaped metal plate. The manufacturing apparatus 100 includes a press working device 200, a magnet attaching device 300, a resin supply device 400, a removal device 500, and a controller Ctr.

[0039] The press working device 200 is configured to form a blanking component W from a metal plate by pressing the metal plate while intermittently feeding the strip-shaped metal plate. The press working device 200 is configured to sequentially laminate a plurality of formed blanking components W to form a stacked body 2. After the stacked body 2 is mounted on the transport jig 10, the stacked body 2 is transported to the magnet attaching device 300 (see FIG. 1 ) by, for example, the transport unit Cv1. Figure 2 ). The conveying unit Cv1 and conveying units Cv2 to Cv5 to be described later may be, for example, roller conveyors or belt conveyors.

[0040] like Figure 3 As shown, the transport jig 10 includes a base member 11 and an insertion column 12. The base member 11 is configured to be able to place the stacked body 2. The base member 11 may have a plate shape. The base member 11 may include a plurality of resin flow paths 13. The resin flow paths 13 may include, for example, recesses 13a and through-holes 13b.

[0041] The recess 13a opens toward the lower surface of the base member 11. The recess 13a may be a groove (so-called flow channel groove) provided to extend along the lower surface of the base member 11, or may constitute a receiving space capable of receiving the end of the plunger 431 to be described later. The through hole 13b penetrates the base member 11 in the height direction (thickness direction) of the base member 11 to reach the upper surface of the base member 11 from the bottom surface of the recess 13a. The respective outlets of the plurality of through holes 13b (openings on the upper surface side of the base member 11) may be provided so that, when viewed from above in a state where the stacked body 2 is placed on the conveying jig 10, each outlet overlaps with each magnet insertion hole 5 of the stacked body 2. As Figure 3 As shown, the recess 13 a and / or the through hole 13 b may have a tapered shape that expands as moving from the upper surface toward the lower surface of the base member 11 .

[0042] The insert post 12 is positioned approximately at the center portion of the base member 11 and protrudes upward from the upper surface of the base member 11. The insert post 12 has a columnar shape and has an outer shape corresponding to the shaft hole 2a of the stacked body 2. When the insert post 12 is inserted into the shaft hole 2a and the stacked body 2 is placed on the base member 11, the stacked body 2 is in a state of being mounted on the transport jig 10.

[0043] Return to Figure 2 The magnet attachment device 300 is configured to place one or more permanent magnets 3 in one magnet insertion hole 5. The magnet attachment device 300 may be, for example, a robot. After the permanent magnets 3 are placed in the magnet insertion holes 5, for example, the stacked body 2 is transferred together with the transfer jig 10 to the resin supply device 400 (see FIG. 1 ) by the transfer unit Cv2. Figure 2 Arrow Ar2 in the figure).

[0044] The resin supply device 400 is configured to supply molten resin to the magnet insertion hole 5 provided with the permanent magnet 3. The details of the resin supply device 400 will be described later. After the resin is supplied to the magnet insertion hole 5, the stacked body 2 is transported together with the transport jig 10 to the resin supply device 400 (see FIG. 1 ) by, for example, the transport unit Cv3. Figure 2 Arrow Ar3 in the figure).

[0045] The removal device 500 is configured to remove the laminated body 2 placed on the conveying jig 10 from the conveying jig 10, and thus form the rotor laminated core 1. The rotor laminated core 1 is conveyed to a subsequent device (see FIG. 1 ) by the conveying unit Cv4, for example. Figure 2 The removing device 500 is configured to remove the residual resin R in the resin flow path 13 of the conveying jig 10 (refer to Figure 3 After the residual resin R is removed from the conveying jig 10, the conveying jig 10 is conveyed to the pressing device 200 (see Figure 2 Arrow Ar5 in the figure).

[0046] The controller Ctr is configured to generate signals for operating the respective devices 200 to 500 and the respective conveying units Cv1 to Cv5 based on, for example, a program recorded in a recording medium (not shown) or an operation input from an operator. The controller Ctr is configured to transmit the generated signals to the respective devices 200 to 500 and the respective conveying units Cv1 to Cv5.

[0047] [Resin supply device]

[0048] Next, we will refer to Figure 3 The resin supply device 400 is configured to melt a resin sheet (resin material) to prepare molten resin and supply the molten resin to the magnet insertion hole 5 provided with the permanent magnet 3. The resin supply device 400 includes a lower mold 410, an upper mold 420, and a plurality of extrusion mechanisms 430.

[0049] With the laminate 2 mounted on the transport jig 10, the lower mold 410 is disposed below the transport jig 10 and configured to support the transport jig 10. The lower mold 410 includes a plurality of through-holes 411. The through-holes 411 may extend through the lower mold 410 in the height direction of the lower mold 410. One resin sheet may be accommodated in one through-hole 411, or a plurality of resin sheets may be accommodated in one through-hole 411.

[0050] The upper mold 420 is provided above the conveying jig 10 and is configured to be able to clamp the stacked body 2 and the conveying jig 10 in the height direction together with the lower mold 410. When the upper mold 420 and the lower mold 410 clamp the stacked body 2 and the conveying jig 10, the lower mold 410 and the upper mold 420 are configured to apply a load of a predetermined magnitude to the stacked body 2 in the height direction.

[0051] When the laminated body 2 and the transfer jig 10 are clamped by the lower mold 410 and the upper mold 420, each through hole 411 can be positioned at a position corresponding to each resin flow path 13 of the transfer jig 10. For example, when viewed from above, each through hole 411 can be positioned to partially or completely overlap each resin flow path 13.

[0052] The lower mold 410 may include a heating source 412. The heating source 412 may be configured to operate based on an instruction from a controller Ctr, and may be, for example, a heater. The heating source 412 may be configured to heat the resin sheet contained in each through-hole 411 by heating the lower mold 410. When the resin sheet is heated by the heating source 412, the resin sheet melts and becomes molten resin. The heating source 412 may also be arranged inside the upper mold 420 or outside the lower mold 410 or the upper mold 420. The lower mold 410 or the upper mold 420 may include a heating source 412.

[0053] The extrusion mechanism 430 is configured to extrude molten resin into the magnet insertion hole 5. Each extrusion mechanism 430 includes a plunger 431 and a drive source 432. Each plunger 431 is configured to be inserted into the corresponding through hole 411 from below. Each drive source 432 is configured to operate based on instructions from the controller Ctr. Each drive source 432 is configured to move the corresponding plunger 431 up and down. Therefore, each plunger 431 can be inserted and removed independently of the corresponding through hole 421 by the corresponding drive source 432.

[0054] The extrusion mechanism 430 may include a single drive source 432 connected to a plurality of plungers 431. In this case, the single drive source 432 may be configured to move the plurality of plungers 431 up and down substantially simultaneously. When the molten resin is extruded into the magnet insertion hole 5, the distal end (upper end) of the plunger 431 may stop in the through-hole 411 or in the recess 13a of the resin flow path 13.

[0055] [Remove Device]

[0056] Next, we will refer to the attached Figures 4 to 7 The configuration of the removing device 500 is described in more detail. The removing device 500 includes a collecting unit 510, a holding unit 520, a separating unit 530, an extruding unit 540, and a processing unit 550.

[0057] The collecting unit 510 includes a collecting box 511 , a supporting member 512 , a plurality of lifting rollers 513 , a first stopper 514 (stopper), a second stopper 515 (another stopper), a first pusher 516 , and a second pusher 517 .

[0058] like Figures 4 to 6As shown, the collection box 511 is configured to support the lifting roller 513, the first stopper 514, the second stopper 515, and the holding unit 520. An opening portion 511a that opens upward is formed on the upper surface of the collection box 511. When viewed from above in a state where the conveying jig 10 is placed on the collection unit 510, the size of the opening portion 511a can overlap most of the conveying jig 10.

[0059] Inside the collection box 511, a recessed space SP is formed which communicates with the opening 511a. Figure 4 As shown, the bottom wall surface of the collection box 511 is an inclined surface that descends as it moves toward the processing unit 550. Therefore, the residual resin R falling toward the collection box 511 reaches the inside of the recessed space SP through the opening 511a and slides downward along the inclined surface in the recessed space SP.

[0060] The collection box 511 is connected to a driving source (not shown), and is configured to be moved in the height direction ( Figure 4 The collecting box 511 can be configured to stop at the first to fourth height positions, for example. Figure 4 and Figure 5 As shown, the first height position may be a height corresponding to the conveying unit Cv3. The second height position may be lower than the first height position, or more specifically, may be lower than a height position obtained by subtracting the length of the insertion column 12 from the first height position. The third height position may be a height corresponding to the extrusion unit 540 (refer to Figure 16 The fourth height position may be a height corresponding to the conveying unit Cv5 (refer to Figure 18 ).

[0061] The support member 512 is configured to temporarily support the transport jig 10. The support member 512 includes a base member 512a and a plurality of support protrusions 512b. Figure 5 and 6 As shown, the base member 512a is arranged near the opening portion 511a of the collection box 511. When viewed from above, the base member 512a can partially close the opening portion 511a so that the base member 512a does not overlap with the resin flow path 13 of the conveying fixture 10 when the conveying fixture 10 is supported by the support member 512. In this case, the residual resin R can easily avoid the base member 512a and fall. The base member 512a can be tilted relative to the horizontal surface. For example, the base member 512a may include a tapered surface whose height decreases as it moves toward the outer circumferential edge. In these cases, even when the residual resin R rides on the base member 512a, the residual resin R can easily fall into the collection box 511 through the inclined surface.

[0062] The support protrusions 512b protrude upward from the surface of the base member 512a. All ends of the multiple support protrusions 512b can be positioned at the same height. In this case, since the multiple support protrusions 512b support the conveying jig 10 on a virtual horizontal surface, the conveying jig 10 is stabilized on the support member 512. The support protrusions 512b can be arranged so that when the conveying jig 10 is supported by the support member 512, the support protrusions 512b do not overlap with the resin flow path 13 of the conveying jig 10 when viewed from above. In this case, the residual resin R can easily avoid the support member 512 and fall off.

[0063] The lifting roller 513 is arranged in a horizontal direction perpendicular to the Z direction ( Figure 4 A pair of wheels facing each other in the Y direction (e.g., Figure 4 and 6 As shown, a pair of wheels is provided so that the support member 512 is positioned between them. The interval between the pair of wheels is set so that the interval is narrower than the width of the conveying jig 10. The plurality of lifting rollers 513 are arranged along a direction orthogonal to both the Y direction and the Z direction ( Figure 4 The X direction is also the moving direction of the conveying jig 10 in the collecting unit 510.

[0064] The lifting roller 513 is connected to a driving source (not shown) and is configured to move up and down in the Z direction by the operation of the driving source based on an instruction from the controller Ctr. The lifting roller 513 can be in an elevated position (refer to Figure 5 etc.) and lowered position (refer to Figure 14 The lifting roller 513 is raised or lowered between the upper and lower ends of the support protrusions 512b in the raised position and the lowered position. When the lifting roller 513 is in the lowered position, the lifting roller 513 can be partially or completely positioned in the recessed space SP.

[0065] like Figure 5 and 6 As shown, the first stopper 514 and the second stopper 515 are provided on the collection box 511 so that the opening 511a is positioned therebetween when viewed from above. In other words, the first stopper 514 and the second stopper 515 face each other in the X direction. When the collection box 511 is at the first height position, as shown in FIG. Figure 5 As shown, the second stopper 515 is positioned closer to the transfer unit Cv3 than the first stopper 514 .

[0066] The first stopper 514 is configured to stop the transfer jig 10 transferred from the transfer unit Cv3 to the collection unit 510 at the position of the first stopper 514. Figure 6 As shown, the first stopper 514 may include a pair of plate-shaped members arranged along the Y direction. The spacing distance between the pair of plate-shaped members may be set to be greater than the width of the first pusher 516 so that the first pusher 516 can pass therebetween.

[0067] The second stopper 515 is configured to prevent the transfer jig 10 transferred from the transfer unit Cv3 to the collecting unit 510 from returning to the transfer unit Cv3. Figures 5 to 7 As shown, the second stopper 515 includes a base member 515a, a roller 515b, and a biasing member 515c. The base member 515a extends in the Y direction and has a crank shape with the center position extending below the two end positions. Therefore, the second pusher 517 is prevented from colliding with the center portion of the base member 515a when the second pusher 517 advances and retreats (described later).

[0068] The roller 515b is configured with a pair of wheels rotatably attached to both ends of the base member 515a. The spacing between the pair of wheels constituting the roller 515b is set to be narrower than the width of the conveying jig 10 and can be the same as the spacing between the pair of wheels constituting the lifting roller 513. A biasing member 515c connects the central portion of the base member 515a to the upper surface of the collection box 511. The biasing member 515c is configured to bias the base member 515a and the roller 515b upward. The biasing member 515c can be, for example, a compression coil spring or rubber.

[0069] like Figure 5 and 6 As shown, the first pusher 516 is provided on the side of the first stopper 514 relative to the collection box 511. The first pusher 516 is connected to a drive source (not shown) and is configured to be able to move forward and backward in the X direction by operating the drive source based on instructions from the controller Ctr. When the transport jig 10 is located in the collection unit 510, when the first pusher 516 passes between the pair of plate-like members of the first stopper 514 and extends close to the second stopper 515, the transport jig 10 is extruded from the collection unit 510.

[0070] like Figure 5As shown, the second pusher 517 is provided on the second stopper 515 side (the conveying unit Cv3 side) relative to the collection box 511. The second pusher 517 is connected to a drive source (not shown) and is configured to be able to move forward and backward in the X direction by operation of the drive source based on instructions from the controller Ctr. When the conveying jig 10 is located in the conveying unit Cv3, when the second pusher 517 extends to approach the first stopper 514 without contacting the center portion of the base member 515a of the second stopper 515, the conveying jig 10 is squeezed out of the conveying unit Cv3 to the collection unit 510.

[0071] like Figures 4 to 6 As shown, the holding unit 520 is provided with a pair of holding members 521. The pair of holding members 521 is attached to the collection box 511 so that the opening portion 511a is located therebetween when viewed from above. The pair of holding members 521 face each other in the Y direction.

[0072] The holding member 521 includes a plate-shaped base member 521a and a movable member 521b. The base member 521a is positioned near the opening 511a and extends in the X-direction. The spacing between the pair of base members 512a is set to be the same as or slightly larger than the width of the transport jig 10. Therefore, when the transport jig 10 slides in the X-direction on the lifting rollers 513, the pair of base members 512a serve as guide members.

[0073] The movable member 521b is attached to the upper end portion of the holding member 521. The movable member 521b is connected to a driving source (not shown) and is configured to be movable in the Y direction by the operation of the driving source based on an instruction from the controller Ctr. The movable member 521b is movable between an approach position and a separation position. In the approach position, the movable member 521b approaches the center side of the opening portion 511a in the Y direction (reference position). Figure 4 、 6 In the separated position, the movable member 521b moves away from the opening 511a in the Y direction (refer to Figure 15 wait).

[0074] When the movable member 521b is in the closed position and the lifting roller 513 is in the raised position, the Z-direction spacing between the movable member 521b and the lifting roller 513 is set to be the same as or slightly larger than the thickness of the base member 11 of the transport jig 10. In this case, when the transport jig 10 is positioned on the lifting roller 513, the base member 11 can hardly move in the vertical direction between the lifting roller 513 and the movable member 521b. Therefore, the vertical movement of the transport jig 10 is restricted.

[0075] The separation unit 530 is configured to separate and remove the stacked body 2 mounted on the transport jig 10 from the transport jig 10. Figure 4 As shown, the separation unit 530 is positioned above the collection box 511 to overlap with the opening portion 511a. The separation unit 530 may be positioned above the upper surface of the transfer unit Cv4.

[0076] The separation unit 530 includes a base member 531 and a pair of movable members 532. The base member 531 is connected to a drive source (not shown) and is configured to be movable in the Y direction by the operation of the drive source based on an instruction from the controller Ctr. The base member 531 is movable between a first overlapping position in which the base member 531 overlaps the opening 511a when viewed from above and a second overlapping position in which the base member 531 overlaps the conveying unit Cv4 when viewed from above.

[0077] The pair of movable members 532 are attached to the base member 531 so as to protrude from the base member 531. The pair of movable members 532 may protrude downward from the base member 531 (refer to Figure 4 The pair of movable members 532 may be arranged to protrude in the same direction along the horizontal direction from the base member 531. The pair of movable members 532 may have a plate-like shape and face each other in the Y direction. At least one of the pair of movable members 532 is connected to a drive source (not shown) and is configured to be movable in the Y direction by operation of the drive source based on an instruction from the controller Ctr. For example, at least one of the pair of movable members 532 may be movable in the Y direction so as to generate an approaching state in which the pair of movable members 532 approach each other and a separated state in which the pair of movable members 532 move away from each other.

[0078] In the separated state, the stacked body 2 mounted on the transport jig 10 is placed between the pair of movable members 532, and then the pair of movable members 532 are brought into an approaching state, and thus, the stacked body 2 is clamped by the pair of movable members 532. In order to more reliably clamp the stacked body 2 by the pair of movable members 532, the respective facing surfaces of the pair of movable members 532 may be curved surfaces corresponding to the circumferential surface of the stacked body 2.

[0079] The extrusion unit 540 is configured to extrude the residual resin R, which is the solidified resin remaining in the resin flow path 13 of the transport jig 10, downward from the resin flow path 13. Figure 4 As shown, the extrusion unit 540 includes a base member 541 and a plurality of extrusion protrusions 542 .

[0080] When the base member 531 is in the first overlapping position, the base member 541 is located above the collecting unit 510 and the separating unit 530. In other words, when the base member 531 is in the first overlapping position, the collecting unit 510, the separating unit 530, and the extruding unit 540 are arranged in a row along the Z direction (vertical direction). The base member 541 is removably attached to an immovable object, such as a wall surface (not shown). Therefore, when attached to the immovable object, the base member 541 does not need to move in any of the X direction, Y direction, and Z direction.

[0081] A receiving hole 541a extending in the Z direction is formed at the center portion of the base member 541. The receiving hole 541a may be open to the lower surface of the base member 541. In other words, the receiving hole 541a may be a through hole that penetrates the base member 541, or may be a non-through hole that does not penetrate the base member 541. The opening area and height of the receiving hole 541a are respectively set to be larger than the diameter and height of the insertion post 12 of the transfer jig 10.

[0082] A plurality of extrusion protrusions 542 protrude downward from the lower surface of the base member 541. Each extrusion protrusion 542 can be arranged to overlap with each resin flow path 13 of the base member 11 when viewed from above. The size of the extrusion protrusion 542 is set to be smaller than the size of the through-hole 13b when viewed from above. The height of the extrusion protrusion 542 is not limited as long as the residual resin R can be extruded from the resin flow path 13 by the extrusion protrusion 542.

[0083] The processing unit 550 is configured as an accumulation container for processing the residual resin R collected in the collection box 511. The processing unit 550 is provided adjacent to the collection box 511 when the collection box 511 is at the third height position. When a predetermined amount of residual resin R has accumulated in the processing unit 550, the processing unit 550 can be automatically or manually replaced with another empty processing unit 550. Alternatively, the residual resin R that has reached the inside of the processing unit 550 can be processed each time.

[0084] [Method for manufacturing a rotor laminated core]

[0085] Reference will be made to the attached Figures 2 to 19 A method for manufacturing the rotor laminated core 1 is described. First, as Figure 2 As shown, based on the instruction of the controller Ctr, the press working device 200 punches out the metal plates in sequence while stacking a plurality of punched parts W to form a stacked body 2 (see Figure 19The laminated body 2 discharged from the press working device 200 is mounted on the conveying jig 10 so that each magnet insertion hole 5 and each resin flow path 13 (through hole 13b) at least partially overlap each other. Thereafter, the laminated body 2 is conveyed to the magnet attaching device 300 (refer to FIG. 1 ) together with the conveying jig 10 by the conveying unit Cv1. Figure 2 Arrow Ar1 in the figure).

[0086] Next, based on the instruction of the controller Ctr, the magnet attachment device 300 respectively arranges the permanent magnet 3 in each magnet insertion hole 5 (refer to Figure 19 After that, the laminated body 2 is transferred to the resin supply device 400 (see step S2) by the transfer unit Cv1 together with the transfer jig 10. Figure 2 Arrow Ar2 in the figure).

[0087] Next, the resin supply device 400 operates based on the instructions of the controller Ctr. When the stack 2 and the transfer fixture 10 are fed in, the resin supply device 400 clamps the stack 2 and the transfer fixture 10 between the lower mold 410 and the upper mold 420. Therefore, the stack 2 is pressurized in the height direction. In this state, the resin sheet is supplied to each through hole 411, and the resin sheet is heated by the heating source 412. The heating source 412 can be operated before the resin sheet is supplied to the through hole 411, and the lower mold 410 can be heated to a predetermined temperature in advance.

[0088] When the resin sheet is in a molten state, the driving source 432 drives the plunger 431 based on the instruction of the controller Ctr. Figure 3 As shown, the molten resin in each through hole 411 is supplied to each magnet insertion hole 5 by the plunger 431 (refer to Figure 19 As a result, the magnet-insert hole 5 is filled with the molten resin, and a portion of the molten resin remains in the resin flow path 13. The molten resin in the magnet-insert hole 5 and in the resin flow path 13 is solidified in the interior thereof.

[0089] After that, the stacked body 2 is transported to the removal device 500 (see FIG. Figure 2 At this time, in the removal device 500, as shown in the arrow Ar3. Figure 5 As shown in FIG, the collection box 511 is positioned at a first height position, the lifting roller 513 is positioned at a raised position, and the movable member 521b is positioned at a closed position.

[0090] like Figure 8As shown, when the stacked body 2 and the transport jig 10 reach the downstream end of the transport unit Cv3, the second pusher 517 operates based on the instruction of the controller Ctr to approach the collecting unit 510. Therefore, the base member 11 pushed by the second pusher 517 slides on the transport unit Cv3, the roller 515b and the lift roller 513 while being guided in the Y direction by the pair of base members 521a and in the Z direction by the lift roller 513 and the movable member 521b until it reaches the first stopper 514. As a result, as shown in FIG. Figure 9 As shown, the stack 2 and the transfer jig 10 are placed on the collecting unit 510 (refer to Figure 19 At this time, the outer peripheral surface of the stacked body 2 partially overlaps with the pair of movable members 532 of the separation unit 530 in the Y direction.

[0091] Since the roller 515b is biased upward by the biasing member 515c, the roller 515b moves upward once the base member 11 passes through the roller 515b. Therefore, the base member 11 is less likely to return to the conveying unit Cv3 side by the roller 515b.

[0092] Next, based on the instruction of the controller Ctr, at least one of the pair of movable members 532 is operated so that the pair of movable members 532 are close to each other. Therefore, the outer peripheral surface of the stacked body 2 is clamped by the pair of movable members 532 (refer to Figure 10 While maintaining this clamping state, based on the instruction of the controller Ctr, the collection box 511 is lowered to the second height position (reference Figure 11 ). At this time, the base member 11 is positioned between the lifting roller 513 and the movable member 521b in the Z direction and is held by the lifting roller 513 and the movable member 521b, and therefore, the movement toward the stacked body 2 is restricted. Figure 12 As shown in detail in FIG, the laminated body 2 is separated from the conveying jig 10, and the resin solidified in the magnet insertion hole 5 and the resin solidified in the resin flow path 13 are separated from each other between the lower end surface of the laminated body 2 and the upper surface of the base member 11 (refer to FIG. Figure 19 5. Thus, the solidified resin 4 is formed in the magnet insertion holes 5, and the rotor laminated core 1 is completed. In addition, when the solidified resin remains in the resin flow path 13, the residual resin R is formed.

[0093] Next, based on the instruction of the controller Ctr, the base member 531 moves in the Y direction to be positioned at the second overlapping position (refer to FIG. Figure 13). Thus, the rotor laminated core 1 is placed on the conveying unit Cv4. Next, based on an instruction from the controller Ctr, at least one of the pair of movable members 532 is activated, so that a separated state is achieved in which the pair of movable members 532 are moved away from each other. Thus, the grip of the outer peripheral surface of the laminated body 2 by the pair of movable members 532 is released, and the rotor laminated core 1 is conveyed to a subsequent process via the conveying unit Cv4.

[0094] At the same time, in the collection box 511 at the second height position, the lifting roller 513 is lowered to the lowered position (refer to Figure 13 and 14 ). Therefore, the transport jig 10 is supported on the support protrusion 512b. Figure 13 and 14 As shown, the base member 11 is positioned in the X direction by the first stopper 514 and the base member 515a and in the Y direction by a pair of base members 521a (see Figure 19 Step S6 in ).

[0095] Next, the pair of movable members 521b moves to the separated position (refer to Figure 13 In this state, the collection box 511 is raised to the third height position (reference Figure 15 When the collecting box 511 is raised until the insertion column 12 is accommodated in the accommodation hole 541a and the upper surface of the base member 11 abuts against or approaches the lower surface of the base member 541, each extrusion protrusion 542 downwardly extrude the residual resin R in the corresponding resin flow path 13 (refer to Figure 15 ). Therefore, the residual resin R falls from the resin flow path 13 into the collection box 511. Therefore, the residual resin R is removed from the resin flow path 13 (refer to Figure 19 The residual resin R collected in the collecting box 511 slides downward along the bottom wall surface (inclined surface) of the collecting box 511 and is accumulated in the processing unit 550 (refer to Figure 17 ).

[0096] Next, based on the instruction of the controller Ctr, the lifting roller 513 is raised to the raised position (refer to Figure 17 ). Therefore, the conveying jig 10 is supported by the lifting roller 513. Next, the collecting box 511 is lowered to the fourth height position (reference Figure 17 ). Therefore, the height of the lifting roller 513 and the height of the conveying unit Cv5 are substantially equal to each other (refer to Figure 18 ).

[0097] Next, based on the instruction of the controller Ctr, the first pusher 516 operates to pass between the pair of plate-shaped members of the first stopper 514 so as to extend toward the second stopper 515 (refer to FIG. Figure 18 ). Therefore, the base member 11 pushed by the first pusher 516 slides on the lifting roller 513, the roller 515b and the conveying unit Cv5 while being guided in the Y direction by the pair of base members 521a. Therefore, the conveying jig 10 is extruded to the conveying unit Cv5 and conveyed (returned) by the conveying unit Cv5 to the pressing device 200 (refer to Figure 19 Step S8 in the process).

[0098] Next, based on the instruction of the controller Ctr, the pair of movable members 521b moves to the close position. The collection box 511 is raised to the first height position based on the instruction of the controller Ctr. Therefore, the removal device 500 returns to Figure 4 After that, the following steps are repeated: receiving the next laminated body 2 and the conveying jig 10; separating the laminated body 2 and the conveying jig 10 from each other; removing the residual resin R from the resin flow path 13; conveying the rotor laminated core 1 to a subsequent process; and conveying the conveying jig 10 to a press working device.

[0099] [effect]

[0100] According to the example described above, after the molten resin is supplied to the magnet insertion hole 5, when the stacked body 2 and the conveying jig 10 are conveyed to the collecting unit 510, the solidified resin in the resin flow path 13 is integrally connected to the solidified resin in the magnet insertion hole 5. Therefore, when the conveying jig 10 moves, the residual resin R does not fall off from the resin flow path 13. Both the separation of the stacked body 2 from the conveying jig 10 and the extrusion of the residual resin R from the resin flow path 13 by the extrusion unit 540 are performed in a state where the conveying jig 10 is placed on the collecting unit 510. Therefore, the residual resin R in the resin flow path 13 is extruded by the extrusion unit 540 and collected in the collecting unit 510. In addition, even if the residual resin R accidentally drips from the resin flow path 13 before being extruded by the extrusion unit 540 due to, for example, vibration during the removal of the stacked body 2 from the conveying jig 10 or vibration generated in the conveying jig 10 until the residual resin R is extruded by the extrusion unit 540, the fallen residual resin R is also collected in the collecting unit 510. Therefore, the transport jig 10 moves to the next process in a state where the residual resin R is removed from the resin flow path 13. According to the above, it is possible to prevent the residual resin R that has fallen from the transport jig 10 from being scattered around.

[0101] According to the above example, the recessed portion 13a and / or the through hole 13b constituting the resin flow path 13 may have a tapered shape that expands as it moves from the upper surface of the base member 11 toward the lower surface. In this case, when the residual resin R in the resin flow path 13 is squeezed from above by the extrusion unit 540, the residual resin R easily falls downward. Therefore, the residual resin R can be effectively removed from the resin flow path 13.

[0102] According to the above example, the collecting unit 510 and the extruding unit 540 overlap each other in the Z direction (vertical direction), and by raising the collecting box 511 so that the collecting box 511 approaches the extruding unit 540, the residual resin R is extruded from the resin flow path 13 by the extruding protrusion 542. Therefore, since the moving distance of the collecting box 511 becomes shorter, the removing device 500 for removing the residual resin R is made compact. In this case, since a driving source for moving the extruding unit 540 is not required, the removing device 500 for removing the residual resin R can be configured at a low cost.

[0103] According to the example described above, the residual resin R that has fallen into and been collected in the collection box 511 is discharged to the processing unit 550, which is arranged adjacent to the collection box 511 at the third height position. Therefore, since the processing unit 550 does not move, the removal device 500 for removing the residual resin R can be made compact. Because the residual resin R collected in the collection box 511 is appropriately discharged to the processing unit, there is no need to stop the collection unit 510 to process the residual resin R. Consequently, the manufacturing efficiency of the rotor laminated core 1 can be improved.

[0104] According to the above example, an opening portion 511a that opens upward is formed on the upper surface of the collection box 511. In a state where the conveying jig 10 is placed on the collection unit 510, the size of the opening portion 511a can overlap with most of the conveying jig 10 when viewed from above. In this case, even when the position of the resin flow path 13 changes, the resin flow path 13 can overlap with the opening portion 511a when the conveying jig 10 is placed on the collection unit 510. Therefore, the residual resin R extruded from the resin flow path 13 by the extrusion unit 540 easily falls into the collection box 511 through the opening portion 511a. Therefore, it is no longer necessary to prepare different types of collection boxes 511 separately according to different types of stacks 2. Therefore, it is possible to configure the removal device 500 for removing the residual resin R at a low cost while corresponding to different types of stacks 2. On the upper surface of the collection box 511, a plurality of opening portions corresponding to two or more resin flow paths 13 can be formed, or a plurality of opening portions corresponding one to one to a plurality of resin flow paths 13 can be formed.

[0105] According to the above example, the base member 541 is removably attached to an immovable object, such as a wall surface (not shown). Therefore, the base member 541 can be replaced with another base member 541 having a different arrangement of extrusion protrusions 542. In this case, the extrusion unit 540 can be replaced relatively easily and inexpensively. Therefore, the removal device 500 for removing the residual resin R can be configured at low cost while corresponding to different types of laminates 2.

[0106] According to the example described above, when the stacked body 2 and the transport jig 10 are separated from each other, the base member 11 is positioned between the elevating rollers 513 and the movable member 521b in the Z direction and is held by the elevating rollers 513 and the movable member 521b. Therefore, the movement of the transport jig 10 toward the stacked body 2 is restricted. As a result, the stacked body 2 can be removed more smoothly from the transport jig 10.

[0107] According to the above example, after separating the laminated body 2 from the transport jig 10, the pair of movable members 521b are moved to the separated position. Consequently, the lifting rollers 513 and the movable members 521b release their grip on the transport jig 10. Consequently, the extrusion unit 540 is less likely to be blocked by the movable members 521b as it approaches the transport jig 10. Consequently, the extrusion unit 540 can more accurately extrude the residual resin R.

[0108] According to the above example, the stop position of the transport jig 10 transported from the transport unit Cv3 to the collection unit 510 is defined by the first stopper 514. Therefore, positional deviation of the transport jig 10 relative to the collection box 511 in the X direction can be prevented.

[0109] According to the above example, when the transport jig 10 is supported on the support protrusion 512b, the transport jig 10 is positioned in the X direction by the first stopper 514 and the base member 515a. Therefore, the positional deviation of the transport jig 10 relative to the collection box 511 in the X direction can be more reliably prevented.

[0110] [Modify example]

[0111] The disclosure in this specification should be considered as illustrative in all aspects and not restrictive. Various omissions, substitutions, changes, etc. can be made with respect to the above examples without departing from the scope of the claims and their gist.

[0112] (1) When the plurality of resin sheets are accommodated in one through-hole 411 , the sizes and / or materials of the resin sheets may be the same or different.

[0113] (2) In the above example, the resin sheet T, that is, the solid resin material, is accommodated in the through-hole 411 , but a liquid or powdery resin material may be accommodated in the through-hole 411 .

[0114] (3) In the above example, the collection box 511 moves up and down so that the collection box 511 approaches or moves away from the fixed base member 541, but the base member 541 can also be configured to move up and down. Alternatively, the collection box 511 and the base member 541 can be configured not to approach or move away from each other along the Z direction.

[0115] (4) In the above example, the extrusion protrusion 542 is fixed to the base member 541, but instead of the extrusion protrusion 542, the extrusion unit 540 may include an extrusion pin that can move up and down relative to the base member 541. In this case, even when the base member 541 is not close to the base member 11 of the transport jig 10, the extrusion pin advances toward below the base member 541, and thus the residual resin R can be extruded from the resin flow path 13. Therefore, the movable member 521b of the holding unit 520 can be in the close position without moving, or can be fixed to the base member 521a.

[0116] (5) The technology can be applied to core products other than the rotor laminated core 1. Other core products may be, for example, a stator laminated core, a non-laminated stator core, and a non-laminated rotor core. The stator core may be a split type stator core formed by combining a plurality of core pieces, or may be a non-split type stator core. The non-split type stator laminated core may be formed by laminating a plurality of punched components W having a circular shape. Alternatively, in the non-split type stator laminated core, a plurality of teeth may be provided on a single yoke, or a plurality of folded type punched components having an annular shape formed by folding between the teeth may be stacked. In the non-laminated rotor core or stator core, ferromagnetic powder may be formed by compression molding, or a resin material containing ferromagnetic powder may be formed by injection molding.

[0117] (6) This technology can be applied to a method for manufacturing a core product, including a process for filling a resin injection unit (e.g., a through-hole, a groove, etc.) extending in the height direction with molten resin. For example, this technology can be applied when a resin film is provided between a stator core and a winding on the inner peripheral surface of a slot of the stator core. Alternatively, this technology can be applied when a through-hole provided in the laminated body 2 is filled with molten resin to join a plurality of blanking parts W.

[0118] (7) In the above example, the stacked body 2 discharged from the pressing apparatus 200 is mounted on the conveying jig 10 conveyed from the removing apparatus 500 to the pressing apparatus 200. However, the process of mounting the stacked body 2 on the conveying jig 10 may be performed in a mounting apparatus different from the pressing apparatus 200. In this case, the stacked body 2 discharged from the pressing apparatus 200 and the conveying jig 10 discharged from the removing apparatus 500 are respectively conveyed to the mounting apparatus through different conveying units. When the stacked body 2 is mounted on the conveying jig 10 in the mounting apparatus, the stacked body 2 is conveyed to the magnet attaching apparatus 300 together with the conveying jig 10 through a conveying unit extending between the mounting apparatus and the magnet attaching apparatus.

[0119] [Other examples]

[0120] <Example 1>

[0121] An example of a method for manufacturing a core product (1) may include: placing a core body (2) on a conveying jig (10) so that a resin forming area (5) provided in the core body (2) communicates with a resin flow path (13) of the conveying jig (10), supplying molten resin to the resin forming area (5) through a resin flow path (13) using a resin supply device (400); after supplying the molten resin, by conveying the conveying jig (10) together with the core body (2) from the resin supply device (400) to a collecting unit (510), placing the conveying jig (10) on the collecting unit (510); and placing the conveying jig (10) on the collecting unit (510). After being placed in a collecting unit (510), a core product (1) including a core body (2) and a solidified resin (4) formed in a resin forming region (5) is obtained by removing the core body (2) from a conveying jig (10) and separating the solidified resin in the resin forming region (5) from the solidified resin in the resin flow path (13), and residual resin (R) as a residue of the solidified resin is formed in the resin flow path (13); and after the residual resin (R) is formed, an extrusion unit (540) is pressed against the residual resin (R) from above and the residual resin (R) is dropped from the resin flow path (13) into the collecting unit (510). In this case, after supplying molten resin, the solidified resin in the resin flow path is integrally connected to the solidified resin in the resin forming region while the core body and the conveying jig are conveyed to the collecting unit. Therefore, when the conveying jig is moved between devices, the residual resin does not fall off from the resin flow path. In a state where the conveying jig is placed on the collecting unit, separation of the core body from the conveying jig and extrusion of the residual resin from the resin flow path by the extrusion unit are performed. Therefore, the residual resin in the resin flow path is extruded by the extrusion unit and collected in the collecting unit. In addition, even when the residual resin accidentally falls from the resin flow path before being extruded by the extrusion unit due to, for example, vibrations during the removal of the core body from the conveying jig or vibrations generated in the conveying jig until the residual resin is extruded by the extrusion unit, the fallen residual resin is also collected in the collecting unit. Therefore, in a state where the residual resin has been removed from the resin flow path, the conveying jig moves to the next process. According to the above content, it is possible to prevent the residual resin that has fallen from the conveying jig from spreading to the surroundings.

[0122] <Example 2>

[0123] In the method according to Example 1, the resin flow path (13) may be a through hole that passes through the transfer jig (10) in the vertical direction, and the through hole may have a tapered shape that increases in area as it moves downward. In this case, when the residual resin in the resin flow path is pressed from above by the extrusion unit, the residual resin easily falls downward. Therefore, the residual resin can be effectively removed from the resin flow path.

[0124] <Example 3>

[0125] In the method according to Example 1 or 2, dropping the residual resin (R) may include moving at least one of the collecting unit (510) and the extruding unit (540) in the vertical direction so that the collecting unit (510) and the extruding unit (540) arranged to overlap each other in the vertical direction are close to each other. In this case, since the moving distance of the collecting unit or the extruding unit is shortened, the removal device for removing the residual resin can be made compact.

[0126] <Example 4>

[0127] In the method according to any one of Examples 1 to 3, causing the residual resin (R) to drop may include raising the collecting unit (510) toward the extrusion unit (540) to a raised position where the collecting unit (510) abuts against the extrusion unit (540), and causing the residual resin (R) to drop from the resin flow path (13) into the collecting unit (510). In this case, since a drive source for moving the extrusion unit is not required, the removal device for removing the residual resin can be configured at low cost.

[0128] <Example 5>

[0129] In the method according to Example 4, causing the residual resin (R) to drop may include discharging the residual resin (R) that has fallen from the resin flow path (13) into the collection unit (510) through the collection unit (510) located at an elevated position to the processing unit (550) located near the collection unit (510). In this case, since the processing unit does not move, the removal device for removing the residual resin can be made compact. Since the residual resin collected in the collection unit is appropriately discharged to the processing unit, it is not necessary to stop the collection unit to process the residual resin. Therefore, it is possible to improve the manufacturing efficiency of the core product.

[0130] <Example 6>

[0131] In the method according to any one of Examples 1 to 5, the collecting unit (510) may include an opening portion (511a) through which the residual resin (R) falling from the resin flow path (13) can pass, and when viewed from a vertical direction, the opening portion is larger than the resin flow path (13). Depending on the type (e.g., size) of the core product, the position of the resin forming area relative to the core body can be changed, and accordingly, the position of the resin flow path of the conveying fixture can also be changed. However, in the case of Example 6, since a relatively large opening portion is formed in the collecting unit, when the conveying fixture is placed on the collecting unit, the resin flow path may overlap with the opening portion even if the position of the resin flow path changes. Therefore, the residual resin squeezed out from the resin flow path by the extrusion unit easily falls into the collecting unit through the opening. Therefore, it is no longer necessary to separately prepare different types of collecting units according to different types of core products. It is therefore possible to configure a removal device for removing residual resin at a low cost while corresponding to different types of core products.

[0132] <Example 7>

[0133] In the method according to any one of Examples 1 to 6, the extrusion unit (540) can be replaced with another extrusion unit (540) according to the type of the core body (2). Incidentally, the extrusion unit can be replaced relatively easily and inexpensively. Therefore, in the case of Example 7, the removal device for removing the residual resin can be configured at low cost while corresponding to different types of core products.

[0134] <Example 8>

[0135] In the method according to any one of Examples 1 to 7, placing the transport jig (10) on the collecting unit (510) may include holding the transport jig (10) placed on the collecting unit (510) between the collecting unit (510) and the holding unit (520) in the vertical direction. In this case, due to the fact that the transport jig is held by the collecting unit and the holding unit, the movement of the transport jig in the vertical direction is restricted. Therefore, the core body can be removed from the transport jig more smoothly.

[0136] <Example 9>

[0137] In the method according to Example 8, dropping the residual resin (R) may include releasing the holding of the conveying jig (10) by the collecting unit (510) and the holding unit (520). In this case, access between the extrusion unit and the conveying jig is less likely to be obstructed by the holding unit. Therefore, the extrusion of the residual resin by the extrusion unit can be performed more accurately.

[0138] <Example 10>

[0139] In the method according to any one of Examples 1 to 9, placing the transport jig (10) on the collecting unit (510) may include limiting the movement of the transport jig (10) by a stopper (514), the stopper (514) defining a stop position of the transport jig (510) relative to the collecting unit (510). In this case, it is possible to prevent the transport jig from being horizontally positioned relative to the collecting unit.

[0140] <Example 11>

[0141] In the method according to Example 10, placing the transport jig (10) on the collecting unit (510) may include limiting the movement of the transport jig (10) in the arrangement direction of the stopper (514) and the other stopper (515) by providing another stopper (515) on the opposite side of the stopper (514) relative to the transport jig (10) at the stopped position. In this case, it is possible to more reliably prevent the transport jig from being positionally deviated in the horizontal direction relative to the collecting unit.

[0142] <Example 12>

[0143] An example of a method for removing residual resin (R) may include: placing the conveying jig (10) on a collecting unit (510) by conveying the conveying jig (10) together with the core body (2) to a collecting unit (510) in a state where the core body (2) is placed on the conveying jig (10) so that a resin forming region (5) provided in the core body (2) is communicated with a resin flow path (13) of the conveying jig (10) and in a state where a cured resin is integrally formed inside the resin forming region (5) and the resin flow path (13); After placing the conveying jig (10) in the collecting unit (510), the core body (2) is removed from the conveying jig (10) and the solidified resin in the resin forming region (5) is separated from the solidified resin in the resin flow path (13), thereby forming residual resin (R) as a residue of the solidified resin in the resin flow path (13); and after the residual resin (R) is formed, the extrusion unit (540) is pressed against the residual resin (R) from above and the residual resin (R) is dropped from the resin flow path (13) to the collecting unit (510). In this case, the same effect as that of the method according to Example 1 is obtained.

[0144] <Example 13>

[0145] An example of a device (500) for removing residual resin (R) may include: a conveying unit (Cv3) configured to convey a conveying jig (10) on which a core body (2) is placed, wherein a resin forming region (5) is provided in the core body (2), and a resin flow path (13) is provided in the conveying jig (10) that communicates with the resin forming region (5) when the core body (2) is placed on the conveying jig (10); and a collecting unit (510) configured to be able to convey the resin (5) to the conveying jig. A jig (10) is placed thereon, the conveying jig (10) being conveyed by the conveying unit (Cv3); a separating unit (530) configured to remove the conveying jig (10) and the core body (2) placed on the collecting unit (510) from each other; and an extruding unit (540) configured to extrude the residual resin (R) remaining in the resin flow path (13) of the conveying jig (10) downward toward the collecting unit (510) after the core body (2) is removed by the separating unit (530). In this case, the same effect as that of the method according to Example 1 is obtained.

Claims

1. A method for manufacturing a core product, the method comprising: supplying molten resin to the resin forming area via the resin flow path using a resin supply device in a state where the core body is placed on a conveying jig so that a resin forming area provided in the core body is communicatively connected to a resin flow path of the conveying jig; After supplying the molten resin, placing the conveying jig on the collecting unit by conveying the conveying jig together with the core body from the resin supply device to the collecting unit; after placing the conveying jig in the collecting unit, separating the resin solidified in the resin forming region from the resin solidified in the resin flow path by removing the core body from the conveying jig; forming a residual resin which is a residue of the solidified resin in the resin flow path by the separation and obtaining the core product, wherein the residual resin includes the core body and the solidified resin formed in the resin forming region; as well as After the residual resin is formed, the residual resin is dropped from the resin flow path into the collecting unit by causing an extrusion unit to abut against the residual resin from above.

2. The method according to claim 1, wherein The dropping of the residual resin includes moving at least one of the collecting unit and the extruding unit in a vertical direction so that the collecting unit and the extruding unit, which are disposed to overlap each other in the vertical direction, approach each other.

3. The method according to claim 1 or 2, wherein: Dropping the residual resin includes dropping the residual resin from a resin flow path into the collecting unit by raising the collecting unit toward the extruding unit to a raised position in which the collecting unit abuts against the extruding unit.

4. A method for removing residual resin, the method comprising: In a state where a core body is placed on a conveying jig such that a resin forming region provided in the core body and a resin flow path of the conveying jig are communicatively connected, the core body and the conveying jig having solidified resin integrally formed in the resin forming region and in the resin flow path are placed on the collecting unit by conveying the conveying jig together with the core body to the collecting unit, thereby placing the conveying jig on the collecting unit; after placing the conveying jig in the collecting unit, separating the resin solidified in the resin forming region from the resin solidified in the resin flow path by removing the core body from the conveying jig; forming residual resin by the separation, the residual resin being a residue of the solidified resin in the resin flow path; and After the residual resin is formed, the residual resin is dropped from the resin flow path to the collecting unit by causing an extrusion unit to abut against the residual resin from above.

5. The method according to claim 4, wherein Dropping the residual resin includes moving at least one of the collecting unit and the extruding unit in a vertical direction so that the collecting unit and the extruding unit, which are disposed overlapping with each other in the vertical direction, approach each other.

6. The method according to claim 4 or 5, wherein: Dropping the residual resin includes dropping the residual resin from the resin flow path into the collecting unit by raising the collecting unit toward the extruding unit to a raised position in which the collecting unit abuts against the extruding unit.

7. A device for removing residual resin, comprising: a conveying unit configured to convey a conveying jig on which a core body is placed, the core body having a resin forming area, the conveying jig having a resin flow path communicatively connected to the resin forming area in a state in which the core body is placed on the conveying jig; a collecting unit configured to place the transfer fixture thereon; a separation unit configured to separate the transport jig placed on the collecting unit and the core body placed on the transport jig from each other; as well as An extrusion unit configured to extrude residual resin remaining in the resin flow path of the transport jig in a state after the core body is removed by the separation unit downward to the collection unit.

8. The apparatus according to claim 7, further comprising a controller for controlling the collecting unit and the extruding unit, wherein: The collecting unit and the extruding unit are arranged to overlap each other in a vertical direction, and The controller is configured to bring the collecting unit and the extruding unit closer to each other by moving at least one of the collecting unit and the extruding unit along the vertical direction.

9. The device according to claim 7 or 8, further comprising a controller for controlling the collecting unit and the extruding unit, wherein: The collecting unit and the extruding unit are arranged to overlap each other in a vertical direction, and The controller is configured to raise the collecting unit toward the extrusion unit to a raised position in which the collecting unit abuts the extrusion unit.

Images