Method for manufacturing a composite forming part and composite forming part

Abstract

The purpose is to further improve the rib-based sealing performance. In a manufacturing method of a composite formed part, the composite formed part includes an internal part, a primary formed part covering the internal part, and a secondary formed part covering the primary formed part. A rib protruding toward the secondary formed part side is formed in the primary formed part. The manufacturing method of the composite formed part includes the following steps: (a) disposing an intermediate part including the internal part and the primary formed part in a mold; (b) causing resin for the secondary formed part to flow into the mold; (c) detecting the temperature of the resin for the secondary formed part in the mold; (d) based on the resin temperature, obtaining a meltable time during which the resin for the secondary formed part in the mold can melt the rib of the primary formed part; (e) determining whether the melting state of the rib is good based on the meltable time; (f) taking out the composite formed part from the mold.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a composite molded part and a composite molded part. Background Art

[0002] Patent Document 1 discloses a case where a molded body in which a detection unit including a detection element portion and a bracket portion are integrated is formed by injection molding or the like, and a case where a resin molded portion is formed by further performing injection molding or the like on the molded body.

[0003] Patent Document 2 discloses a case where the surface temperature and heat flux of a mold cavity are measured by a temperature sensor, and the molding conditions are controlled by comparing the measured values with reference values.

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2017-96828

[0007] Patent Document 2: Japanese Unexamined Patent Application Publication No. 63-126717 Summary of the Invention

[0008] Outline of the Invention

[0009] Problems to be Solved by the Invention

[0010] Ribs are sometimes provided to seal between the primary molded part and the secondary molded part. Further improvement in the sealing performance based on the ribs is required.

[0011] Therefore, an object of the present disclosure is to further improve the sealing performance based on the ribs.

[0012] Means for Solving the Problems

[0013] In the method for manufacturing a composite molded part of the present disclosure, the composite molded part includes an internal part, a primary molded part covering the internal part, and a secondary molded part covering the primary molded part. A rib portion protruding toward the secondary molded part side is formed in the primary molded part. The method for manufacturing the composite molded part includes the following steps: (a) disposing an intermediate part including the internal part and the primary molded part in a mold; (b) causing resin for the secondary molded part to flow into the mold; (c) detecting the temperature of the resin for the secondary molded part in the mold; (d) based on the resin temperature, obtaining a meltable time during which the resin for the secondary molded part in the mold can melt the rib portion of the primary molded part; (e) determining whether the melting state of the rib portion is good based on the meltable time; (f) taking out the composite molded part from the mold.

[0014] In addition, the composite molded part of the present disclosure includes: an internal part; a primary molded part covering the internal part; and a secondary molded part covering the primary molded part. A rib protruding toward the secondary molded part side is formed in the primary molded part, and a sensor imprint is formed on the surface of the secondary molded part.

[0015] Advantageous Effects of the Invention

[0016] According to the present disclosure, the sealing performance based on the rib can be further improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic top view of a mold device used in the manufacturing method of the composite molded part.

[0018] Figure 2 It is a block diagram of a manufacturing device of a composite molded part used in the manufacturing method of the composite molded part.

[0019] Figure 3 It is a schematic perspective view of the composite molded part.

[0020] Figure 4 It is a partial cross-sectional view of the composite molded part.

[0021] Figure 5 It is a flowchart showing the manufacturing method of the composite molded part.

[0022] Figure 6 It is a flowchart showing a processing example of the control device.

[0023] Figure 7 It is a graph showing a change example of the resin temperature with respect to time.

[0024] Figure 8 It is a flowchart showing the processing of a modification example.

[0025] Figure 9 It is a flowchart showing the processing of another modification example.

[0026] Figure 10 It is a flowchart showing the processing of still another modification example.

[0027] Figure 11 It is a flowchart showing the processing of yet another modification example. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0028] [Description of Embodiments of the Present Disclosure]

[0029] First, embodiments of the present disclosure will be listed and described.

[0030] The manufacturing method of the composite molded part of the present disclosure is as follows.

[0031] (1) A manufacturing method of a composite formed part, the composite formed part having an internal part, a primary formed part covering the internal part, and a secondary formed part covering the primary formed part, wherein a rib protruding toward the secondary formed part side is formed in the primary formed part, and the manufacturing method of the composite formed part includes the following steps: (a) disposing an intermediate part including the internal part and the primary formed part in a mold; (b) flowing resin for the secondary formed part into the mold; (c) detecting the temperature of the resin for the secondary formed part in the mold; (d) based on the resin temperature, obtaining a meltable time during which the resin for the secondary formed part in the mold can melt the rib of the primary formed part; (e) based on the meltable time, determining whether the melting state of the rib is good; (f) taking out the composite formed part from the mold. Based on the resin temperature, obtaining the meltable time during which the resin for the secondary formed part in the mold can melt the rib of the primary formed part, and based on this meltable time, determining whether the melting state of the rib is good, so that the melting state of the rib can be determined more accurately. By grasping the melting state of the rib, the sealing performance based on the rib can be further improved.

[0032] (2) In the manufacturing method of the composite formed part according to (1), it may further include the following step: (g) when it is determined in the step (f) that the melting state of the rib is poor, discarding the composite formed part taken out from the mold. The composite formed part can be easily discarded when it is determined that the melting state of the rib is poor.

[0033] (3) In the manufacturing method of the composite formed part according to (1) or (2), it may further include the following step: (h) when it is determined that the melting state of the rib is poor, changing the forming conditions for the next time. It can suppress the occurrence of defects during the next mold forming.

[0034] (4) In the manufacturing method of the composite formed part in any one of (1) to (3), in the step (e), it may be determined whether the melting state of the rib is good based on the integral value of the resin temperature with respect to the meltable time. Referring to the meltable time and the resin temperature, it can be determined whether the melting state of the rib is good.

[0035] (5) In the manufacturing method of the composite formed part in any one of (1) to (4), it may further include the following step: (i) based on a first temperature sensor and a second temperature sensor separately provided in the mold, obtaining the inflow rate of the resin for the secondary formed part in the mold. The inflow state of the resin into the mold can be monitored.

[0036] (6) In the method for manufacturing a composite molded part according to any one of (1) to (5), the following step may also be included: (j) determining whether the internal part satisfies the thermal condition based on the resin temperature for the secondary forming part within the mold. It is possible to determine whether the internal part satisfies the thermal condition.

[0037] (7) In the method for manufacturing a composite molded part according to any one of (1) to (6), in the step (c), the resin temperature for the secondary forming part within the mold may be the temperature on the surface extension of the portion of the resin for the secondary forming part that covers the rib. Based on the resin temperature near the rib, the melting state of the rib can be determined more accurately.

[0038] (8) In the method for manufacturing a composite molded part according to any one of (1) to (7), (k) may also be based on a pressure sensor provided near an end of the mold surface within the mold that is far from the resin injection port for the secondary forming part, determining the filling state of the resin for the secondary forming part into the mold. It is possible to determine whether the resin for the secondary forming part into the mold is firmly filled.

[0039] The composite molded part of the present disclosure is as follows.

[0040] (9) The composite molded part includes: an internal part; a primary forming part that covers the internal part; and a secondary forming part that covers the primary forming part. A rib protruding toward the secondary forming part side is formed in the primary forming part, and a sensor imprint is formed on the surface of the secondary forming part. Since the sensor imprint is formed on the surface of the secondary forming part, based on the sensor disposed in the sensor imprint, the conditions during the mold forming of the secondary forming part can be known. Thereby, it is possible to contribute to further improving the sealing performance based on the rib.

[0041] (10) In the composite molded part of (9), the sensor imprint may also include a first sensor imprint and a second sensor imprint that are separately formed on the surface of the secondary forming part. The conditions of the resin for the secondary forming part can be grasped at the separated positions.

[0042] (11) In the composite molded part of (9) or (10), a resin injection port imprint may be formed on the surface of the secondary forming part, and an end sensor imprint may be formed near an end of the surface of the secondary forming part that is far from the resin injection port imprint. It is possible to determine whether the resin for the secondary forming part into the mold is firmly filled.

[0043] [Details of the Embodiment of the Present Disclosure]

[0044] Hereinafter, with reference to the drawings, a method for manufacturing a composite molded part and a specific example of the composite molded part of the present disclosure will be described. It should be noted that the present disclosure is not limited to these examples, and is disclosed in the claims and is intended to include all changes within the meaning equivalent to the claims and the scope thereof.

[0045] [Embodiment]

[0046] Hereinafter, a method for manufacturing a composite molded part and the composite molded part of the embodiment will be described.

[0047] [Regarding the composite molded part and the manufacturing apparatus for the composite molded part]

[0048] Figure 1 It is a schematic top view showing a mold apparatus 30 used in the method for manufacturing a composite molded part. Figure 2 It is a block diagram showing a manufacturing apparatus 10 for a composite molded part used in the method for manufacturing a composite molded part. In Figure 2 it shows Figure 1 a cross-sectional view taken along line II-II of the mold apparatus 30. Figure 3 It is a schematic perspective view showing a composite molded part 50. In Figure 3 it shows a state in which two composite molded parts 50 are connected via a runner mark portion 70. Figure 4 It is a partial cross-sectional view of the composite molded part 50.

[0049] The composite molded part 50 includes an internal part 52, a primary molded portion 54, and a secondary molded portion 56. In Figures 1 to 3 a threaded fastening portion 51 for threadedly fastening the composite molded part 50 to an installation target portion is also integrally formed on the secondary molded portion 56. The threaded fastening portion 51 may be omitted.

[0050] The internal part 52 is a part covered by the primary molded portion 54 and the secondary molded portion 56, and is, for example, an electrical component (refer to Figure 1 ). More specifically, the internal part 52 is a sensor element that detects physical quantities such as magnetism, light, and temperature or changes in them. Terminals of the internal part 52 are connected to the core wires of the electric wire W. The electric wire W passes through the inside of the primary molded portion 54 and the secondary molded portion 56 and extends to the outside. The output signal of the internal part can be output to the outside via the electric wire W.

[0051] The primary forming part 54 and the secondary forming part 56 cover the internal component 52. Here, the primary forming part 54 and the secondary forming part 56 are parts formed of resin. The primary forming part 54 and the secondary forming part 56 can also be formed of, for example, PE (polyethylene), polyamide, PBT (polybutylene terephthalate), etc. The primary forming part 54 is the part that holds the internal component 52. The secondary forming part 56 is the part that covers the primary forming part 54. By setting it to the state where the internal component 52 is buried in the primary forming part 54 and the secondary forming part 56, the sealing performance for the internal component 52 can be improved.

[0052] More specifically, the primary forming part 54 is the part that covers the internal component 52. In the state where the primary forming part 54 covers the internal component 52, the integrated part of the two is the intermediate component 54M. For example, the primary forming part 54 is the part formed by die molding with the internal component 52 as the inserted component. In Figure 2 it shows the state where the primary forming part 54 covering the internal component 52 is positioned in the mold device 30. The primary forming part 54 is formed in a rectangular parallelepiped shape. The internal component 52 is accommodated at a position near one main surface at one end in the length direction of the primary forming part 54. The electric wire W connected to the internal component 52 passes through the primary forming part 54 and extends toward the other end side of the primary forming part 54. It should be noted that the primary forming part 54 does not need to cover the whole of the internal component 52, as long as it covers at least a part of the internal component 52. It is not necessary to die mold the primary forming part 54 with the internal component 52 as the inserted component. The primary forming part 54 can also be die molded into a shape that can accommodate the internal component 52, and the internal component 52 can be inserted into the primary forming part 54.

[0053] The secondary forming part 56 covers the primary forming part 54. The secondary forming part 56 can cover the whole of the periphery of the primary forming part 54, or can cover a part of the primary forming part 54. Here, the secondary forming part 56 covers the whole of the periphery of the primary forming part 54 except for the part used for positioning in the primary forming part 54. That is, in the mold device 30, the primary forming part 54 is positioned at a certain position by the positioning pin 31P protruding into the mold space (refer to Figure 4 ).

[0054] The outer shape of the secondary forming part 56 is formed in an elongated rectangular parallelepiped shape. The internal component 52 is set to the state of being buried in a part near one end in the secondary forming part 56. The electric wire W passes through the secondary forming part 56 again from one end of the primary forming part 54 and extends outward from the other end of the secondary forming part 56. It should be noted that the outer shape of the secondary forming part 56 does not have to be a rectangular parallelepiped.

[0055] In the primary forming section 54, a rib portion 55 is formed which protrudes toward the secondary forming section 56. The rib portion 55 serves to more reliably suppress the case where water seeps along the boundary between the primary forming section 54 and the secondary forming section 56.

[0056] That is, in the secondary forming section 56, a hole 56h reaching the primary forming section 54 is formed from its surface (refer to Figure 4 ). When the secondary forming section 56 is die-formed with the internal component 52 and the primary forming section 54 as inserts, the primary forming section 54 is positioned and held by the positioning pin 30P as described above. The rib portion 55 is an annular rib portion that surrounds the hole 56h. The rib portion 55 is preferably formed to be wider toward the front end side in the protruding direction. Here, the positioning pin 30P can be inserted into the center of the rib portion 55 on the surface of the primary forming section 54, and a bottomed hole 54h with a bottom is formed. By inserting the positioning pin 30P into the bottomed hole 54h, the primary forming section 54 can be positioned more accurately when the secondary forming section 56 is die-formed. It is not necessary to form the bottomed hole 54h. The above bottomed hole 54h does not reach the internal component 52.

[0057] When the secondary forming section 56 is die-formed with the primary forming section 54 as an insert, the heated and molten resin for forming the secondary forming section 56 is injected into the mold device 30. When the heated and molten resin comes into contact with the surface of the primary forming section 54, it rapidly cools and solidifies. The heated and molten resin at the front end portion of the rib portion 55 does not rapidly cool as in the case of coming into contact with the surface of the primary forming section 54. Therefore, it is expected that the heated and molten resin for forming the secondary forming section 56 fuses with the front end portion of the rib portion 55. As a result, more complete waterproofing is performed along the rib portion 55 at the boundary between the primary forming section 54 and the secondary forming section 56. The above rib portion 55 is sometimes also called a melting rib. In order to facilitate the fusion of the rib portion 55 with the secondary forming section 56, the primary forming section 54 and the secondary forming section 56 are preferably formed of the same material.

[0058] Especially when the above positioning hole 56h is formed, the boundary between the primary forming section 54 and the secondary forming section 56 is exposed to the outside through the hole 56h. Therefore, the rib portion 55 is formed so as to surround the hole 56h. Thereby, it is possible to suppress the case where water is transmitted to between the primary forming section 54 and the secondary forming section 56 via the hole 56h and further transmitted to the internal component 52.

[0059] In order to further improve the waterproof effect of the above rib portion 55, it is preferable that the front end portion of the rib portion 55 fuses with the resin forming the secondary forming section 56 (hereinafter sometimes referred to as "fusion state"). However, since the rib portion 55 itself is in a state of being buried in the secondary forming section 56, it is not possible to directly confirm whether the above fusion state is achieved even when observing the manufactured composite formed component 50.

[0060] In order to more reliably fuse the front end of the rib 55 with the resin forming the secondary molded portion 56, measures such as increasing the temperature of the resin for the secondary molded portion 56 injected into the mold device 30 as much as possible or extending the time for which the temperature of the resin for the secondary molded portion 56 is kept at a high temperature in the mold device 30 may be considered. However, there are limitations on increasing the resin temperature or extending the time for which the temperature is kept at a high temperature in the mold device 30 in view of the thermal influence on the internal component 52 and the requirement to shorten the mold molding time as much as possible.

[0061] Under such background, the present disclosure relates to a technology for more reliably fusing the front end portion of the rib with the resin forming the secondary molded portion 56 , thereby further improving the sealing performance by the rib.

[0062] The composite molded component manufacturing apparatus 10 used in the manufacturing method of the composite molded component 50 of the present disclosure includes a mold device 30 , a resin injection device 60 , and a control device 20 .

[0063] The mold device 30 includes an upper mold 32 and a lower mold 36. The upper mold 32 and the lower mold 36 constitute a mold 38 for molding the composite molded component 50. A mold surface 38F for molding the surface of the secondary molded portion 56 is formed in the mold 38. In the mold surface 38F, a mold space into which a resin for forming the secondary molded portion 56 flows becomes wider. In the present embodiment, the upper mold 32 and the lower mold 36 are divided into a portion for holding the electric wire W and other portions, but this is not essential.

[0064] In the present embodiment, a plurality of (here, two) mold surfaces 38F are formed in the mold device 30. A flow path 31b such as a runner that branches from an inlet 31a midway and heads toward injection ports 31c that open respectively on a plurality of mold surfaces 38F is formed in the mold device 30. Here, the flow path 31b is formed into a shape including a portion that branches into a T-shape. A flow path imprint portion 70 corresponding to the flow path 31b is connected to a side portion near the other end portion of the secondary molding portion 56. Therefore, if the flow path imprint portion 70 is cut off from the secondary molding portion 56, a resin injection port imprint P1 will remain on one side portion of the other end portion of the secondary molding portion 56.

[0065] Temperature sensors 40 and 42 are provided in the mold 38. Here, the temperature sensors 40 and 42 are provided in the upper mold 32. More specifically, a through hole is provided from the surface of the upper mold 32 toward the mold surface 38F. The temperature sensors 40 and 42 are arranged to penetrate the through hole. The temperature detection surface of one end of the temperature sensor 40 and 42 is exposed to the mold surface 38F, and the resin temperature in the mold space can be detected on the extension of the mold surface 38F. The other end of the temperature sensor 40 and 42 is exposed to the outside of the upper mold 32, and the detection signal is output through other wires and the like.

[0066] The positioning pin 30P in the upper die 32 contacts the primary forming portion 54 in the die 38 from above. A rib portion 55 is formed in a portion of the primary forming portion 54 that surrounds the positioning pin 30P of the upper die 32 (see Figure 2 and Figure 4 ). Therefore, the temperature detection surfaces of the temperature sensors 40 and 42 are located on the surface extension of the resin for the secondary forming portion 56 and cover the portion of the rib portion 55. Thus, the resin temperature detected by the temperature sensors 40 and 42 is the resin temperature for the secondary forming portion 56 in the die 38 and the temperature on the surface extension of the portion of the resin for the secondary forming portion 56 that covers the rib portion 55. The positions where the temperature sensors 40 and 42 are provided are preferably positions close to the rib portion 55. For example, positions near the rib portion 55 are preferred. The thickness of the secondary forming portion 56 at the portion where the temperature sensors 40 and 42 are provided is preferably the same as the thickness of the secondary forming portion 56 at the portion where the rib portion 55 is provided. The temperature sensors 40 and 42 may also be provided at other positions, such as portions on the lower die 36 side, portions on one side of the secondary forming portion 56, etc.

[0067] In addition, in the present embodiment, the temperature sensors 40 and 42 include a first temperature sensor 40 and a second temperature sensor 42. The first temperature sensor 40 and the second temperature sensor 42 are provided at separated positions. Preferably, the first temperature sensor 40 and the second temperature sensor 42 are provided at positions that are at different distances from the resin injection port 31c. It should be noted that the distance between the first temperature sensor 40 and the second temperature sensor 42 is a known value determined in the design.

[0068] The die surface 38F and the temperature detection surfaces of the temperature sensors 40 and 42 are arranged to be as flush as possible, but a slight gap or height difference may be formed. Therefore, the imprints of the temperature sensors 40 and 42 remain on the surface of the secondary forming portion 56. In the present embodiment, a first sensor imprint 56a1 and a second sensor imprint 56a2 remain separated from the surface of the secondary forming portion 56.

[0069] In addition, a pressure sensor 44 is provided in the die 38. Here, the pressure sensor 44 is provided in the upper die 32. More specifically, a through-hole is provided from the surface of the upper die 32 toward the die surface 38F. The pressure sensor is arranged to penetrate through the through-hole. One end portion of the pressure sensor 44 has a pressure detection surface exposed to the die surface 38F, and the resin pressure in the die space can be detected on the extension of the die surface 38F. The other end portion of the pressure sensor 44 is exposed to the outside of the upper die 32, and a detection signal is output via other wires or the like.

[0070] The pressure sensor 44 is disposed near the end separated from the resin injection port 31c for the secondary forming portion 56. That is, the pressure sensor 44 is disposed at a position near the opposite side of the injection port 31c in the length direction of the secondary forming portion 56. The pressure sensor 44 is preferably within 1 cm from the end of the secondary forming portion 56 or the like, and as close as possible to the end of the secondary forming portion 56. Here, the pressure sensor 44 is separated from the injection port 31c more than the above temperature sensors 40 and 42. The pressure sensor 44 is disposed at a position opposite to the internal component 52.

[0071] The mold surface 38F and the temperature detection surface of the pressure sensor 44 are arranged as much as possible in the same planar shape, but a minute gap or height difference may be formed. Therefore, the imprint of the pressure sensor 44 remains on the surface of the secondary forming portion 56. In the present embodiment, the pressure sensor imprint 56a3 remains on the surface of the secondary forming portion 56 separately from the above injection port imprint P1.

[0072] A heater 39 may be loaded into the mold device 30. By this heater 39, the mold temperature can also be controlled.

[0073] The heated and molten resin for the secondary forming portion 56 is supplied from the resin injection device 60. The heated and molten resin is injected into the mold device 30 through the injection port 31c.

[0074] The control device 20 is composed of a computer in which a CPU 21, a storage unit 22, etc. are connected to each other via a bus. The storage unit 22 is a ROM, a RAM, etc. A program 22a, a condition value 22b, etc. are stored in the storage unit 22. The CPU 21 is a processor. The program 22a may also be installed from an external server device or the like. The program 22a may also be circulated in a state stored in a recording medium such as a CD-ROM, a DVD-ROM, or a semiconductor memory.

[0075] The control device 20 is connected to the temperature sensors 40 and 42 and the pressure sensor 44 via an input / output interface. The outputs of the temperature sensors 40 and 42 and the pressure sensor 44 are given to the control device 20.

[0076] The control device 20 is connected to the resin injection device 60 and the heater 39 via an input / output interface. The control device 20 can control the injection time, injection pressure, injection temperature, etc. based on the resin injection device 60. Moreover, the control device 20 controls the heater 39 to be able to perform temperature control of the mold device 30.

[0077] In addition, the control device 20 can also be connected to the molded product take-out device 80 via the input / output interface. The molded product take-out device 80 is a device that takes out the composite molded part 50 from the mold device 30 and transfers it to a recycling section 84, 86 such as a container. The molded product take-out device 80 can also be realized by an orthogonal robot or a vertical articulated robot having a hand capable of gripping the composite molded part 50. As the recycling sections 84, 86, a recycling section 84 for good products and a recycling section 86 for defective products are prepared in advance, and the molded product take-out device 80 can also transfer the composite molded part 50 separately to the recycling sections 84, 86. A control example for this case will be described later.

[0078] The CPU 21 performs arithmetic processing in accordance with the sequence described in the program 22a, whereby the following processing based on the output results of the temperature sensors 40, 42, the pressure sensor 44, etc. can be executed for the manufacture of the composite molded part 50.

[0079] It should be noted that the present disclosure can be realized not only as the control device 20 having such a characteristic processing section, but also as a manufacturing method in which the above characteristic processing is set as a step, or as a program for causing a computer to execute the above steps. Moreover, it can be realized as a semiconductor integrated circuit that realizes part or all of the control device, or as a manufacturing system including the control device.

[0080] According to the above composite molded part 50, sensor imprints 56a1, 56a2, 56a3 are formed on the surface of the secondary molding section 56. Therefore, based on the sensors 40, 42, 44 arranged at the sensor imprints of these sensor imprints 56a1, 56a2, 56a3, the conditions during die molding of the secondary molding section 56 can be known. Thereby, it is possible to contribute to further improving the sealing performance based on the rib 55.

[0081] In addition, the first sensor imprint 56a1 and the second sensor imprint 56a2 are separately formed on the surface of the secondary molding section 56, so that the resin temperature for the secondary molding section 56 can be grasped at separate positions. Thus, for example, the resin inflow rate can be grasped.

[0082] In addition, the sensor imprint 56a3 is formed near the end portion of the surface of the secondary molding section 56 that is separated from the resin injection port imprint P1, so that it is possible to determine whether the resin is firmly filled in the mold space.

[0083] <Regarding the manufacturing method of the composite molded part>

[0084] Figure 5 It is a flowchart showing the manufacturing method of the composite molded part 50. The manufacturing method of the composite molded part 50 includes the following steps S1 to S6. Figure 5Each of the steps shown can be executed by a computer or by a person.

[0085] Step S1 is the step (a) of setting the intermediate member 54M in the mold device 30. That is, the intermediate member 54M is set in the mold device 30 in such a manner that the intermediate member 54M is positioned by the positioning pins 30P (see Figure 2 ). This step can be carried out by a robot that holds the intermediate member 54M or by hand.

[0086] Step S2 is the step (b) of causing the resin for the secondary forming portion 56 to flow into the mold space in the mold 38. For example, the control device 20 controls the resin injection device 60 to inject the heated and molten resin from the resin injection device 60 into the mold space.

[0087] Step S3 is the step (c) of detecting the temperature of the resin for the secondary forming portion 56 in the mold 38. For example, the detection signals of the first temperature sensor 40 and the second temperature sensor 42 installed in the mold device 30 are output to the control device 20. Thus, in the control device 20, the resin temperature can be grasped.

[0088] Step S4 is the step (d) of obtaining the meltable time during which the resin for the secondary forming portion 56 in the mold 38 can melt the primary forming portion 54 based on the resin temperature. That is, if the temperature of the heated and molten resin for the secondary forming portion 56 is equal to or higher than the temperature at which the resin forming the primary forming portion 54 melts, the state in which the rib portion 55 in the primary forming portion 54 is mixed with the resin for the secondary forming portion 56 can be ensured. The meltable time is, for example, the duration during which the detected resin temperature becomes equal to or higher than the temperature at which the resin forming the rib portion 55 of the primary forming portion 54 melts. The temperature at which the resin melts can be the melting point or the glass transition temperature of the resin forming the primary forming portion 54, or a reference temperature set based on the melting point or the glass transition temperature. For example, the measurement positions of the temperature sensors 40 and 42 are at the position of the mold surface 38F and separated from the primary forming portion 54. In order to grasp the melting state of the rib portion 55, it is desirable to estimate the temperature of the resin for the secondary forming portion 56 at the boundary between the primary forming portion 54 and the secondary forming portion 56. Therefore, a temperature that is a specified temperature higher than the detection temperature of the temperature sensors 40 and 42 can also be set as the reference temperature.

[0089] Step S5 is step (e) of determining a good product of the melting state of rib 55 based on the meltable time. That is, if the meltable time is short, rib 55 is hardly melted, and the melting state is considered poor. Moreover, if the meltable time is long, rib 55 is sufficiently melted, and the melting state is considered good. Therefore, based on the meltable time, a good product of the melting state of rib 55 can be determined. In this determination, not only the meltable time but also other factors, such as the resin temperature, can be considered simultaneously. Later, an example of determining whether it is good by considering the meltable time and the resin temperature will be described.

[0090] Step S6 is step (f) of removing the composite molded part 50 from the mold 38. This step can be performed by a robot holding the intermediate part 54M or by hand.

[0091] The above steps S2 to S5 are performed by the control device 20 which is a computer, and the flowchart of its processing is as Figure 6 shown.

[0092] In step S11, the control device 20 sets the molding conditions. The molding conditions are the pressure of the resin injection device 60, the resin temperature, the heating temperature of the mold 38, etc. For example, at the start of the operation, the preset initial values are set as the molding conditions.

[0093] In the next step S12, the control device 20 gives an instruction to the resin injection device 60 to start injection. Thereby, the heated and melted resin is injected into the mold space of the mold 38 from the resin injection device 60.

[0094] In the next step S13, based on the outputs from the temperature sensors 40 and 42, the resin temperature is obtained.

[0095] In the next step S14, based on the resin temperature, the meltable time can be obtained. Figure 7 is a diagram showing an example of the change in the resin temperature. As shown in this diagram, the resin temperature detected by the temperature sensors 40 and 42 shows a change of rising sharply due to the injection of the heated and melted resin into the mold 38 and then gradually decreasing. Here, if the reference temperature a for melting the resin of rib 55 forming the primary molded part 54 is set, the resin temperature becomes the reference temperature a at time t1. When the resin temperature exceeds the peak and continues to decrease, it becomes the reference temperature a at time t2. The time when the resin temperature becomes above the reference temperature is the time from time t1 to time t2, so the meltable time becomes t2 - t1.

[0096] Steps S15 and S16 show a specific example of the above step S5. In step S15, the integral value of the resin temperature in the meltable time is obtained ( Figure 7(area of the slanted region in). For example, for the discrete data of the detected resin temperature, perform numerical integration during the above-mentioned meltable time to obtain the integrated value of the resin temperature during the meltable time. The longer the meltable time, the larger the above-mentioned integrated value, and the higher the resin temperature, the larger the above-mentioned integrated value. That is, the integrated value represents a value that reflects the meltable time and the resin temperature. The integrated value can also be obtained for the value after subtracting a constant (for example, the value obtained by subtracting the above-mentioned reference temperature from the temperature).

[0097] In step S16, it is determined whether the integrated value is less than the reference value. The reference value is determined by experimentally manufacturing the composite molded part 50 at various actual temperatures and observing whether the melting state of the rib 55 of the manufactured composite molded part 50 is good. For example, it is also possible to conduct a test on whether air leakage occurs between the primary forming part 54 and the secondary forming part 56, and determine whether the melting state of the rib 55 is good based on the presence or absence of air leakage. Or, it is also possible to cut the composite molded part 50 and observe the melting condition of the rib 55 to determine whether the melting state of the rib 55 is good. Also, the above-mentioned reference value can be determined at the boundary between the condition where the melting state of the rib 55 is good and the condition where it is bad. When the integrated value exceeds the reference value, proceed to step S17 and determine it as a good product. When the integrated value does not exceed the reference value, proceed to step S18 and give a bad warning. When the integrated value is the same as the reference value, it can be determined as a good product or as a bad one. The bad warning is given by the warning device 62. As the warning device 62, display devices such as a light-emitting part, a monitor, etc., or a speaker that emits sound can be used. The bad warning is given by the situation of displaying the bad warning through the display device or the situation of emitting a warning sound of the bad content through the speaker.

[0098] In the case where multiple temperature sensors 40, 42 are provided, the above-mentioned steps S14 to S16 can also be respectively performed on the detection results of the multiple temperature sensors 40, 42, and when it is determined to be bad based on at least one detection result, it is determined to be bad. Or, the above-mentioned steps S14 to S16 can be performed on the average value of the detection results of the multiple temperature sensors 40, 42.

[0099] The example of the process for making the good or bad determination is not limited to the above example. For example, it is also possible to make the good or bad determination by comparing the meltable time with a specified reference time. Moreover, it is also possible to make the good or bad determination by comparing the product or sum of the meltable time and the maximum value or average value of the resin temperature within the meltable time with a specified reference value.

[0100] After the end of step S17 or S18, the process proceeds to step S19. In step S19, it is determined whether the forming is completed. Whether the forming is completed is determined by, for example, determining whether the forming of a regular number of parts has been completed based on the setting of the number of parts to be manufactured that has been input in advance. When it is determined that the forming is not completed, the process returns to step S12 and the above processing is repeated. When it is determined that the forming is completed, the process ends.

[0101] According to the manufacturing method of the composite molded part 50 configured in this way, based on the resin temperature, the meltable time during which the resin for the secondary molding part 56 in the mold 38 can melt the rib part 55 of the primary molding part 54 is obtained, and based on this meltable time, it is determined whether the melting state of the rib part 55 is good. Therefore, the melting state of the rib part 55 can be determined more accurately. By grasping the melting state of the rib part 55, the sealing performance based on the rib part 55 can be further improved.

[0102] In particular, based on the integral value of the resin temperature within the meltable time, it is determined whether the melting state of the rib part 55 is good. Therefore, by taking the meltable time and the resin temperature into consideration, it is possible to more accurately determine whether the melting state of the rib part 55 is good.

[0103] In addition, the resin temperature of the secondary molding part 56 is the temperature on the surface extension of the part of the resin for the secondary molding part 56 that covers the rib part 55. Therefore, based on the resin temperature near the rib part 55, the melting state of the rib part 55 can be determined more accurately.

[0104] <Modification example related to the manufacturing method of the composite molded part>

[0105] Regarding the above manufacturing method, it may also include step (g) of discarding the composite molded part 50 taken out from the mold 38 when it is determined that the melting state of the rib part 55 is poor.

[0106] In addition, regarding the above manufacturing method, it may also include step (h) of changing the following forming conditions when it is determined that the melting state of the rib part 55 is poor.

[0107] The flowchart of this modification example is as Figure 8 shown. In Figure 8 it, in the flowchart shown in Figure 6 after step S18, step S21 and step S22 are added. That is, after it is determined to be poor (in Figure 8(after step S18 in [the above]), in step S21, a discard operation control is performed. The discard operation control is the control corresponding to the above step (g). For example, the control device 20 can control the molded product take-out device 80 to take out the composite molded part 50 from the mold 38 and transfer it to the recycling section 86 for defective products. It should be noted that in the case where it is determined to be a good product (step S17), the control device 20 can control the molded product take-out device 80 to take out the composite molded part 50 from the mold 38 and transfer it to the recycling section 84 for good products. The operator can also observe the above warning display or listen to the warning sound to discard the composite molded part 50 taken out from the mold 38.

[0108] In addition, in the next step S22, a change of the molding conditions is performed. This step S22 is the control corresponding to the above step (h). For example, in the case where the integral value does not exceed the reference value, it can be considered that the heating is insufficient. Therefore, it is possible to consider increasing the set temperature of at least one of the resin temperature of the resin injection device 60 and the mold temperature of the mold device 30. It should be noted that in the case where the integral value largely exceeds the reference value, it can be considered that the heating is excessive. Therefore, conversely to the above, it is possible to consider decreasing the set temperature of at least one of the resin temperature of the resin injection device 60 and the mold temperature of the mold device 30. Thus, in the next mold molding, the resin becomes hotter and the rib 55 melts more reliably.

[0109] By this modification example, it is possible to easily discard the composite molded part 50 in the case where it is determined that the melting state of the rib 55 is defective.

[0110] In addition, it is possible to suppress the case where the melting state of the rib 55 continuously becomes defective. It should be noted that in the case where it is determined based on the outputs of the temperature sensors 40 and 42 that the temperature of the heated molten resin is too low compared to the specified temperature, it is also possible to perform feedback control such as increasing the temperature of the heater 39 of the mold 38.

[0111] Regarding the above manufacturing method, it may also include a step (i) of obtaining the inflow rate of the resin for the secondary molding part 56 in the mold 38 based on the first temperature sensor 40 and the second temperature sensor 42.

[0112] The flowchart of this modification example is as Figure 9 shown. In Figure 9 it, in Figure 6In the flowchart shown, steps S31 and S32 are added after step S16. That is, when it is determined in step S16 that the integral value exceeds the reference value, step S31 is entered. In step S31, the inflow velocity can be obtained. Since the two temperature sensors 40 and 42 are provided at specified positions of the mold 38, the distance between the two temperature sensors 40 and 42 is a value known in design. Moreover, by applying the outputs of the two temperature sensors 40 and 42 to the control device 20, the time for the resin to pass through the positions corresponding to the two temperature sensors 40 and 42 can be obtained. For example, the time when the temperature based on the output results of the two temperature sensors 40 and 42 exceeds a specified reference value can be determined as the time for the resin to pass through the position corresponding to the temperature sensor 40. And by dividing the distance between the two temperature sensors 40 and 42 by the difference in the time for the resin to pass through the positions corresponding to the two temperature sensors 40 and 42, the inflow velocity of the resin can be obtained.

[0113] In the next step S32, it can be determined whether the inflow velocity of the resin satisfies the specified inflow conditions. For example, if the inflow velocity is slow, there may be a situation where the resin is not sufficiently melted or the pressure is insufficient. Therefore, a lower limit inflow velocity can be preset as the inflow condition, and it can be specified that the inflow velocity exceeds this lower limit inflow velocity. The lower limit inflow velocity can also be obtained experimentally or empirically. In the case where the inflow velocity of the resin does not satisfy the specified inflow conditions, it is considered defective, and step S18 is entered to give a defective warning. In the case where the inflow velocity of the resin satisfies the specified inflow conditions, it is considered a good product, and step S17 is entered.

[0114] According to this modification example, based on the inflow velocity of the resin flowing into the mold 38, it is monitored whether the inflow state of the resin is more appropriate.

[0115] Regarding the above manufacturing method, it may also include a step (j) of determining whether the thermal conditions of the internal component 52 are satisfied based on the output results of the temperature sensors 40 and 42.

[0116] The flowchart of this modification example is as Figure 10 shown. In Figure 10 it, in Figure 6In the flowchart shown, step S41 is added after step S16. That is, when it is determined in step S16 that the integral value exceeds the reference value, step S41 is entered. In step S41, based on the output results of temperature sensors 40 and 42, it is determined whether the thermal conditions of the internal component 52 are satisfied. The thermal conditions are the temperature conditions that the internal component 52 can withstand and are predetermined in view of the characteristics of the internal component 52, etc. The thermal conditions can be any conditions that reflect the temperature of the molten resin, such as the upper limit value condition for the resin temperature, or can be specified by the conditional time for the time when the resin temperature exceeds the specified temperature, or can also be the upper limit value of the integral value obtained by integrating the resin temperature over the time when it exceeds the specified temperature. The above-mentioned various conditions can also be obtained experimentally and empirically in view of the characteristics of the internal component 52. When it is determined that the thermal conditions are not satisfied, it is considered defective and step S18 is entered. When it is determined that the thermal conditions are satisfied, it is considered a good product and step S17 is entered.

[0117] According to this modification example, it is possible to determine whether the thermal state of the internal component 52 is good, and treat the composite molding component 50 including the overheated internal component 52 as a defective product, thereby suppressing the generation of defects.

[0118] Regarding the above manufacturing method, it may also include a step (k) of determining the filling temperature of the resin for the secondary forming portion 56 in the mold 38 based on the output result of the pressure sensor 44.

[0119] The flowchart of this modification example is as Figure 11 shown. In Figure 11 it, in the Figure 6 shown flowchart, step S51 is added after step S16. That is, when it is determined in step S16 that the integral value exceeds the reference value, step S51 is entered. In step S51, based on the output result of the pressure sensor 44, it is determined whether the pressure conditions are satisfied. The pressure conditions are the pressure conditions when the heated molten resin flows into the mold 38 and are predetermined in view of the characteristics of the internal component 52, etc. If the pressure is too small, the resin may not be sufficiently filled in the end portion deviated from the injection port 31c. Moreover, if the pressure is too large, it can be considered that excessive force is applied to the primary forming portion 54 and the internal component 52. Therefore, appropriate upper and lower limit values are set as the pressure conditions. The upper and lower limit values are set experimentally and empirically in such a way that the resin fills the fine portions evenly and excessive force is not applied to the primary forming portion 54 and the internal component 52. When it is determined that the pressure conditions are not satisfied, it is considered defective and step S18 is entered. When it is determined that the pressure conditions are satisfied, it is considered a good product and step S17 is entered.

[0120] According to this modification example, within the range of avoiding applying a large force to the internal component 52, the primary forming portion 54, etc., it is possible to determine whether the resin for the secondary forming portion 56 is firmly filled in the mold 38.

[0121] It should be noted that the respective structures described in the above-described embodiments and modification examples can be appropriately combined as long as they do not contradict each other.

[0122] Reference Numeral Explanation

[0123] 10 Manufacturing apparatus

[0124] 20 Control apparatus

[0125] 21 CPU

[0126] 22 Storage unit

[0127] 22a Program

[0128] 22b Condition value

[0129] 30 Mold apparatus

[0130] 30P Alignment pin

[0131] 31a Inlet

[0132] 31b Flow path

[0133] 31c Injection port

[0134] 32 Upper mold

[0135] 36 Lower mold

[0136] 38 Mold

[0137] 38F Mold surface

[0138] 39 Heater

[0139] 40 First temperature sensor

[0140] 42 Second temperature sensor

[0141] 44 Pressure sensor

[0142] 50 Composite forming component

[0143] 51 Threaded fastening portion

[0144] 52 Internal component

[0145] 54 Primary forming portion

[0146] 54M Intermediate component

[0147] 54h Bottomed hole

[0148] 55 Rib portion

[0149] 56 Secondary forming section

[0150] 56a1 First sensor imprint

[0151] 56a2 Second sensor imprint

[0152] 56a3 Pressure sensor imprint

[0153] 56h Hole

[0154] 60 Resin injection device

[0155] 62 Warning device

[0156] 70 Runner imprint section

[0157] 80 Molded product take-out device

[0158] 84, 86 Recycling section

[0159] P1 Resin injection port imprint

[0160] W Electric wire.

Claims

1. A manufacturing method of a composite formed component, the composite formed component comprising an internal component, a primary formed portion covering the internal component, and a secondary formed portion covering the primary formed portion, wherein a rib portion protruding toward the secondary formed portion side is formed in the primary formed portion, and The manufacturing method of the composite forming part includes the following steps: (a) Setting an intermediate part including the internal part and the primary forming part in a mold; (b) Making the resin for the secondary forming part flow into the mold; (c) Detecting the temperature of the resin for the secondary forming part in the mold; (d) Based on the resin temperature, obtaining the meltable time during which the resin for the secondary forming part in the mold can melt the rib part of the primary forming part; (e) Judging whether the melting state of the rib part is good based on the meltable time; and (f) Taking out the composite forming part from the mold.

2. The manufacturing method of the composite formed component according to claim 1, wherein The manufacturing method of the composite forming part further includes the following step: (g) When it is judged in the step (f) that the melting state of the rib part is poor, discarding the composite forming part taken out from the mold.

3. The manufacturing method of the composite formed component according to claim 1 or 2, wherein The manufacturing method of the composite forming part further includes the following step: (h) When it is judged that the melting state of the rib part is poor, changing the forming conditions for the next time.

4. The manufacturing method of the composite formed component according to claim 1 or 2, wherein In the step (e), judging whether the melting state of the rib part is good based on the integral value of the resin temperature in the meltable time.

5. The manufacturing method of the composite formed component according to claim 1 or 2, wherein The manufacturing method of the composite forming part further includes the following step: (i) Based on a first temperature sensor and a second temperature sensor separately provided in the mold, obtaining the inflow rate of the resin for the secondary forming part in the mold.

6. The manufacturing method of the composite formed component according to claim 1 or 2, wherein The manufacturing method of the composite forming part further includes the following step: (j) Judging whether the internal part meets the thermal conditions based on the temperature of the resin for the secondary forming part in the mold.

7. The manufacturing method of the composite formed component according to claim 1 or 2, wherein In the step (c), the temperature of the resin for the secondary forming part in the mold is the temperature on the surface extension of the part of the resin for the secondary forming part covering the rib part.

8. The manufacturing method of the composite formed component according to claim 1 or 2, wherein The manufacturing method of the composite forming part further includes the following step: (k) Judging the filling state of the resin for the secondary forming part flowing into the mold based on a pressure sensor provided near the end far from the injection port of the resin for the secondary forming part in the mold surface in the mold.

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