Manufacturing apparatus, manufacturing system, and manufacturing method

Abstract

The present invention relates to a manufacturing apparatus including a defining portion, a plunger, and a valve member. The defining portion defines a supply port, a discharge port, and a resin passage. The resin passage includes a storage portion, a first partial passage connecting the supply port and the storage portion, a second partial passage connecting the storage portion and the discharge port, a relay passage connecting the first partial passage, the storage portion, and the second partial passage, and a connection passage connecting the first partial passage and the second partial passage. The plunger discharges molten resin stored in the storage portion. The valve member is provided in the connection passage and the second partial passage. The first partial passage and the relay passage are connected to the connection passage in a manner intersecting the connection passage. The valve member includes a first valve portion and a second valve portion. The present invention also relates to a manufacturing system and a manufacturing method.

Description

Technical Field

[0001] This disclosure relates to the manufacture of the product. Background Technology

[0002] Injection molding apparatuses capable of manufacturing products by molding multiple molded articles using a single injection operation or by molding multiple molded articles onto a workpiece are generally known. To simultaneously mold multiple articles, multiple cavities corresponding to the shapes of the articles are defined in a mold, and molten resin is injected simultaneously into the multiple cavities. If the multiple cavities have the same shape, multiple molded articles with the same shape can be manufactured; if the multiple cavities have different shapes, multiple molded articles with different shapes can be manufactured. Alternatively, molded articles can be manufactured by injecting molten resin into a single cavity through multiple outlets. In either of these cases, the molten resin is discharged through multiple outlets. When the molten resin is discharged through multiple outlets, it is necessary to control the amount of molten resin discharged through each outlet.

[0003] Japanese Patent Application Publication No. 2001-205656 discloses an injection molding apparatus in which each outlet connected to a cavity is provided with a valve pin. In the injection molding apparatus described in Japanese Patent Application Publication No. 2001-205656, the timing of opening / closing the outlet via the valve pin is controlled according to the capacity of each cavity, thereby controlling the amount of molten resin injected into each cavity.

[0004] Each valve pin is configured to be driven by a drive mechanism including an electric motor, cylinder, etc. In cases where the amount or pressure of resin supplied to each cavity is controlled by controlling the opening / closing timing of each outlet, as described in Japanese Patent Application Publication No. 2001-205656, errors such as time delays between the opening / closing timings of the outlets can occur. These errors can lead to variations in the amount of resin injected into each cavity, or differences in resin pressure within each cavity, which can affect the quality of the molded article. Similarly, injecting molten resin into a single cavity through multiple outlets can also affect the quality of the molded article. Summary of the Invention

[0005] According to a first aspect of the invention, a manufacturing apparatus includes a defining portion, a plunger, and a valve member. The defining portion is configured to define a supply port through which molten resin is supplied, an outlet through which molten resin is discharged, and a resin channel connecting the supply port and the outlet. The resin channel includes a storage portion configured to store molten resin, a first partial channel connecting the supply port and the storage portion, a second partial channel connecting the storage portion and the outlet, a relay channel connecting the first partial channel and the storage portion and connecting the storage portion and the second partial channel, and a connecting channel connecting the first partial channel and the second partial channel. The plunger is movable to change the capacity of the storage portion and is configured to discharge molten resin stored in the storage portion from the outlet by moving to reduce the capacity of the storage portion. The valve member is disposed in the connecting channel and the second partial channel and is movable along the channel direction of the second partial channel. The first partial channel and the relay channel are connected to the connecting channel in a manner that intersects with the connecting channel. The valve component includes a first valve portion and a second valve portion. The first valve portion is configured to open and close the outlet by moving along the channel direction. The second valve portion is configured to open the outlet of the molten resin of the first part of the channel to communicate with the relay channel when the first valve portion has been moved to the position of closing the outlet, and to close the outlet of the first part of the channel when the first valve portion has been moved to the position of opening the outlet.

[0006] According to a second aspect of the invention, a manufacturing apparatus includes a defining portion, a first plunger, a second plunger, a first valve member, and a second valve member. The defining portion is configured to define a supply port through which molten resin is supplied, a first discharge port through which molten resin is discharged, a second discharge port through which molten resin is discharged, a first resin channel connecting the supply port and the first discharge port, and a second resin channel connecting the supply port and the second discharge port. The first resin channel includes a first reservoir configured to store molten resin. The second resin channel includes a second reservoir configured to store molten resin. The first plunger is movable to change the capacity of the first reservoir and is configured to discharge molten resin stored in the first reservoir from the first discharge port by moving to reduce the capacity of the first reservoir. The second plunger is movable to change the capacity of the second reservoir and is configured to discharge molten resin stored in the second reservoir from the second discharge port by moving to reduce the capacity of the second reservoir. The first resin channel includes a first section connecting the supply port and the first storage section, a second section connecting the first storage section and the first outlet, and a first relay channel connecting the first section and the first storage section, and connecting the first storage section and the second section. The second resin channel includes a third section connecting the supply port and the second storage section, a fourth section connecting the second storage section and the second outlet, and a second relay channel connecting the third section and the second storage section, and connecting the second storage section and the fourth section. A first plunger moves to reduce the capacity of the first storage section, discharging molten resin stored in the first storage section from the first outlet via the first relay channel and the second section. A second plunger moves to reduce the capacity of the second storage section, discharging molten resin stored in the second storage section from the second outlet via the second relay channel and the fourth section. The first valve member includes a first valve section and a second valve section. The first valve section is configured to open and close a first outlet when the first valve member moves. The second valve section is configured to open the outlet of molten resin in a first partial channel to communicate with a first relay channel when the first valve section has moved to the position where the first outlet is closed, and to close the outlet of the first partial channel when the first valve section has moved to the position where the first outlet is open. The second valve member includes a third valve section and a fourth valve section. The third valve section is configured to open and close a second outlet when the second valve member moves. The fourth valve section is configured to open the outlet of molten resin in a third partial channel to communicate with a second relay channel when the third valve section has moved to the position where the second outlet is closed, and to close the outlet of the third partial channel when the third valve section has moved to the position where the second outlet is open. The first partial channel is longer than the third partial channel.

[0007] According to a third aspect of the invention, a manufacturing apparatus includes a defining portion, a first plunger, a second plunger, a first heater, and a second heater. The defining portion is configured to define a supply port through which molten resin is supplied, a first outlet port through which molten resin is discharged, a second outlet port through which molten resin is discharged, a first resin channel connecting the supply port and the first outlet port, and a second resin channel connecting the supply port and the second outlet port. The first resin channel includes a first reservoir configured to store molten resin, a first partial channel connecting the supply port and the first reservoir, and a second partial channel connecting the first reservoir and the first outlet port. The second resin channel includes a second reservoir configured to store molten resin, a third partial channel connecting the supply port and the second reservoir, and a fourth partial channel connecting the second reservoir and the second outlet port. The first plunger is movable to change the capacity of the first reservoir and is configured to discharge molten resin stored in the first reservoir from the first outlet port by moving to reduce the capacity of the first reservoir. The second plunger is movable to change the capacity of the second reservoir and is configured to discharge molten resin stored in the second reservoir from the second outlet by moving to reduce the capacity of the second reservoir. The first heater is arranged along a second-part channel. The second heater is arranged along a fourth-part channel. The first plunger discharges molten resin stored in the first reservoir from the first outlet via the second-part channel by moving to reduce the capacity of the first reservoir. The second plunger discharges molten resin stored in the second reservoir from the second outlet via the fourth-part channel by moving to reduce the capacity of the second reservoir. The second-part channel is longer than the fourth-part channel. The first heater is longer than the second heater.

[0008] Other features of the invention will become apparent from the following description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0009] Figure 1 This is a perspective view of the manufacturing apparatus according to the first embodiment.

[0010] Figure 2 This is a longitudinal sectional view of the injection unit according to the first embodiment.

[0011] Figure 3A This is a plan view of the injection unit according to the first embodiment.

[0012] Figure 3B This is a plan view of the injection unit according to the first embodiment.

[0013] Figure 4 This is an explanatory diagram of two resin channels according to the first embodiment.

[0014] Figure 5 This is a perspective view of a portion of the valve pin according to the first embodiment.

[0015] Figure 6A This is a cross-sectional view of the second valve section and its vicinity according to the first embodiment.

[0016] Figure 6B This is a cross-sectional view of the second valve section and its vicinity according to the first embodiment.

[0017] Figure 7A This is a cross-sectional view of the second valve section and its vicinity according to the first embodiment.

[0018] Figure 7B This is a cross-sectional view of the second valve section and its vicinity according to the first embodiment.

[0019] Figure 8 This is a longitudinal sectional view of the injection unit according to the first embodiment.

[0020] Figure 9 This is a longitudinal sectional view of the injection unit according to the first embodiment.

[0021] Figure 10 This is a longitudinal sectional view of the injection unit according to the first embodiment.

[0022] Figure 11 This is a longitudinal sectional view of the injection unit according to the first embodiment.

[0023] Figure 12 This is a longitudinal sectional view of the injection unit according to the first embodiment.

[0024] Figure 13 This is an explanatory diagram of the product according to the first embodiment.

[0025] Figure 14 This is an explanatory diagram of the product according to the first embodiment.

[0026] Figure 15 This is a perspective view of the manufacturing system according to the second embodiment.

[0027] Figure 16 This is an explanatory diagram of the product according to the second embodiment.

[0028] Figure 17 This is a plan view of a part of the manufacturing apparatus according to the third embodiment.

[0029] Figure 18 This is a plan view of a part of the manufacturing apparatus according to the fourth embodiment.

[0030] Figure 19 This is a plan view of a part of the manufacturing apparatus according to the fifth embodiment.

[0031] Figure 20 This is an explanatory diagram of two resin channels of the manufacturing apparatus according to the sixth embodiment. Detailed Implementation

[0032] Exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The manufacturing apparatus according to the present disclosure can be applied to injection molding apparatuses that form products by injecting molten resin into a mold, and to injection molding apparatuses in which workpieces, such as molding parts or metal parts, are placed in the apparatus and products are formed by injecting molten resin onto the workpieces. For example, products can be manufactured by insert molding, outsert molding, or two-color molding. Outsert molding will be described below as an example.

[0033] First Embodiment

[0034] Figure 1 This is a perspective view of the manufacturing apparatus 1000 according to the first embodiment. The manufacturing apparatus 1000 is, for example, a small injection molding apparatus that can be used in a product manufacturing line. A pre-plunger type injection molding apparatus is suitable as a small injection molding apparatus for molding small molded articles. The case where the manufacturing apparatus 1000 is a pre-plunger type injection molding apparatus will be described. In a pre-plunger type injection molding apparatus, the amount of molten resin to be injected into the mold cavity is measured by storing molten resin in a cylinder with a defined storage section.

[0035] The manufacturing apparatus 1000 of the first embodiment is used to manufacture a product by inserting a molded article at each of a plurality of locations on the workpiece 13. The product manufactured by the manufacturing apparatus 1000 can be an intermediate product or a final product.

[0036] The manufacturing apparatus 1000 includes an injection unit 100, a holding member 30 for holding a workpiece 13, and a control device 200 for controlling the injection unit 100. The control device 200 is an example of a controller, such as one or more computers.

[0037] Figure 2 This is a longitudinal sectional view of the injection unit 100 according to the first embodiment. The injection unit 100 includes a resin supply section 46, a plasticizing section 49, a defining section 52, and an injection section 40. The resin supply section 46 is, for example, a hopper. For example, granular resin material is filled into the resin supply section 46. For example, the resin material is a thermoplastic resin. The resin material filled into the resin supply section 46 is supplied to the plasticizing section 49.

[0038] The plasticizing section 49 is connected to a supply port S1 through which molten resin is supplied. The plasticizing section 49 includes a cylinder 47 having a hollow cylindrical shape, a screw 50 disposed within the cylinder 47, and a heater 51 disposed on the outer peripheral surface of the cylinder 47. Resin material is supplied into the cylinder 47 from the resin supply section 46. The cylinder 47 is heated by the heater 51, thereby heating the resin material supplied into the cylinder 47. The heated resin material is then conveyed by the screw 50 to a defining section 52 while being plasticized and melted. The defining section 52 includes multiple components defining multiple resin channels. The resin melted by the plasticizing section 49, i.e., molten resin, is supplied to each resin channel. The direction in which the resin flows within the channel is referred to as the channel direction. Generally, the channel direction coincides with the longitudinal direction of the channel. If the channel has a cylindrical shape, the channel direction coincides with the axial direction of the cylindrical shape.

[0039] Figure 3A and 3B This is a plan view of the injection unit 100 according to the first embodiment. Figure 3A and 3B In each of these, a portion of the injection unit 100 is shown in cross-sectional view. In the first embodiment, as an example of multiple resin channels, three resin channels 521, 522, and 523 through which molten resin flows from the supply port S1 connected to a single plasticizing section 49 to three discharge ports G1, G2, and G3 are defined by a defining section 52. Note that the number of resin channels is not limited to 3, but can be 2, 4, or more.

[0040] Resin channel 521 is an example of a first resin channel, and it connects the outlet G1 and the supply port S1 connected to the plasticizing section 49. Resin channel 522 is an example of a second resin channel, and it connects the outlet G2 and the supply port S1 connected to the plasticizing section 49. Resin channel 523 is an example of a third resin channel, and it connects the outlet G3 and the supply port S1 connected to the plasticizing section 49. In the first embodiment, a main channel 52a shared by multiple resin channels 521, 522, and 523 is defined by a limiting portion 52. The main channel 52a is connected to the supply port S1 connected to the plasticizing section 49.

[0041] Each of the outlets G1, G2, and G3 is a gate through which molten resin is discharged. Outlet G1 is an example of a first outlet. Outlet G2 is an example of a second outlet. Outlet G3 is an example of a third outlet. Outlet G1 is connected to cavity CV1. Outlet G2 is connected to cavity CV2. Outlet G3 is connected to cavity CV3. Cavity CV1 is an example of a first cavity. Cavity CV2 is an example of a second cavity. Cavity CV3 is an example of a third cavity. Molten resin discharged from outlet G1 is injected into cavity CV1, molten resin discharged from outlet G2 is injected into cavity CV2, and molten resin discharged from outlet G3 is injected into cavity CV3. The defining part 52 is heated as a whole by a heater. For example, each cavity CV1, CV2, and CV3 is defined by a mold and workpiece 13.

[0042] Figure 4 This is an explanatory diagram of the two resin channels 521 and 522 according to the first embodiment. Note that in Figure 4 The illustration of resin channel 523 is omitted in the text.

[0043] The resin channel 521 has a storage section 58, a partial channel 52x, a partial channel 52e, and a partial channel 52h. The storage section 58 is an example of a first storage section and is a space capable of storing molten resin supplied from the supply port S1 connected to the plasticizing section 49. The partial channel 52x is an example of a first partial channel and connects the storage section 58 and the supply port S1 connected to the plasticizing section 49. The partial channel 52x includes a main channel 52a and a branch channel 52b. The branch channel 52b is an example of a first branch channel and branches from the main channel 52a. The partial channel 52e is an example of a first relay channel, connecting the storage section 58 and the branch channel 52b of the partial channel 52x, and connecting the storage section 58 and the partial channel 52h. The partial channel 52h is an example of a second partial channel, connecting the partial channel 52e and the discharge port G1. That is, the partial channel 52h connects the storage section 58 and the discharge port G1.

[0044] The resin channel 522 includes a storage section 59, a partial channel 52y, a partial channel 52f, and a partial channel 52i. The storage section 59 is an example of a second storage section and is a space capable of storing molten resin supplied from the supply port S1 connected to the plasticizing section 49. The partial channel 52y is an example of a third partial channel and connects the storage section 59 and the supply port S1 connected to the plasticizing section 49. The partial channel 52y includes a main channel 52a and a branch channel 52c. The branch channel 52c is an example of a second branch channel and branches from the main channel 52a. The partial channel 52f is an example of a second relay channel, connecting the storage section 59 and the branch channel 52c of the partial channel 52y, and connecting the storage section 59 and the partial channel 52i. The partial channel 52i is an example of a fourth partial channel, connecting the partial channel 52f and the discharge port G2. That is, the partial channel 52i connects the storage section 59 and the discharge port G2.

[0045] The resin channel 523 includes a storage section 60, a partial channel 52g, a partial channel 52j, and a partial channel including a main channel 52a and a branch channel 52d. The storage section 60 is an example of a third storage section and is a space capable of storing molten resin supplied from the supply port S1 connected to the plasticizing section 49. The partial channel including the main channel 52a and the branch channel 52d is an example of a fifth partial channel and connects the storage section 60 and the supply port S1 connected to the plasticizing section 49. The branch channel 52d is an example of a third branch channel and branches from the main channel 52a. The partial channel 52g is an example of a third relay channel, connecting the storage section 60 and the branch channel 52d, and also connecting the storage section 60 and the partial channel 52j. The partial channel 52j is an example of a sixth partial channel, connecting the partial channel 52g and the discharge port G3. That is, the partial channel 52j connects the storage section 60 and the discharge port G3.

[0046] As described above, the main channel 52a shared by the three resin channels 521, 522, and 523 is defined within the defining portion 52. Additionally, three branch channels 52b, 52c, and 52d branching from the main channel 52a are defined within the defining portion 52. Each of the branch channels 52b, 52c, and 52d is defined in a curved shape, thus not linearly connected to the main channel 52a. As a result, it is possible to suppress the concentration of molten resin flow in a portion of the branch channel, i.e., to suppress excessively high resin pressure in a portion of the branch channel.

[0047] Furthermore, branch channels 52b, 52c, and 52d are each designed to have different lengths. That is, as shown... Figure 4 As shown, the total length L1 of partial channels 52x and partial channels 52e is different from the total length L2 of partial channels 52y and partial channels 52f.

[0048] The length of a portion of channel 52e is greater than the diameter of a portion of channel 52e. Furthermore, the cross-sectional area of ​​the portion of channel 52e is configured to increase in a stepped manner towards the storage section 58. Additionally, the length of a portion of channel 52f is greater than the diameter of a portion of channel 52f. Furthermore, the cross-sectional area of ​​the portion of channel 52f is configured to increase in a stepped manner towards the storage section 59. The length of a portion of channel 52g is greater than the diameter of a portion of channel 52g. Furthermore, the cross-sectional area of ​​the portion of channel 52g is configured to increase in a stepped manner towards the storage section 60. Therefore, storage sections 58, 59, and 60 can smoothly store molten resin.

[0049] Note that a portion of channel 52e may be configured such that the cross-sectional area of ​​the channel continuously increases toward the storage section 58. Furthermore, a portion of channel 52f may be configured such that the cross-sectional area of ​​the channel continuously increases toward the storage section 59. Additionally, a portion of channel 52g may be configured such that the cross-sectional area of ​​the channel continuously increases toward the storage section 60.

[0050] The injection unit 40 includes plungers 55, 56 and 57, a drive unit 70, valve pins 61, 62 and 63, and a drive unit (not shown) for driving valve pins 61, 62 and 63.

[0051] The plunger 55 is an example of a first plunger and is arranged in the cylinder of the limiting section 52 in such a way that it can move to change the capacity of the storage section 58. By moving to reduce the capacity of the storage section 58, the plunger 55 can inject the molten resin stored in the storage section 58 from the outlet G1 into the cavity CV1 through partial channels 52e and 52h.

[0052] The plunger 56 is an example of a second plunger and is arranged in the cylinder of the limiting section 52 in a manner that allows it to move to change the capacity of the storage section 59. By moving to reduce the capacity of the storage section 59, the plunger 56 can inject the molten resin stored in the storage section 59 from the outlet G2 into the cavity CV2 via partial channels 52f and 52i.

[0053] Plunger 57 is an example of a third plunger and is arranged in the cylinder of the limiting section 52 in a manner that allows it to move to change the capacity of the storage section 60. By moving to reduce the capacity of the storage section 60, plunger 57 can inject molten resin stored in the storage section 60 from the outlet G3 into the cavity CV3 via partial channels 52g and 52j.

[0054] As described above, molten resin can be supplied from a single plasticizing section 49, i.e., from a single supply port S1, to multiple cavities CV1, CV2, and CV3 via multiple resin channels 521, 522, and 523. Furthermore, resin channel 521 includes a storage section 58, resin channel 522 includes a storage section 59, and resin channel 523 includes a storage section 60. Storage section 58 includes a plunger 55, storage section 59 includes a plunger 56, and storage section 60 includes a plunger 57. As a result, molten resin corresponding to the respective capacities of cavities CV1, CV2, and CV3 can be stored in storage sections 58, 59, and 60, and can be injected into cavities CV1, CV2, and CV3 respectively through plungers 55, 56, and 57. Consequently, molded articles formed from cavities CV1, CV2, and CV3 can be manufactured with high precision, thus improving the quality of each molded article. In the first embodiment, multiple molded articles formed on workpiece 13 can be manufactured with high precision, thus improving the quality of the manufactured product. In addition, in the first embodiment, the resin channels 521, 522, and 523 are configured such that molten resin is supplied from a single plasticizing section 49 to storage sections 58, 59, and 60. As a result, it is not necessary to provide multiple plasticizing sections corresponding to multiple storage sections 58, 59, and 60, thus reducing the size of the manufacturing apparatus 1000, i.e., the size of the injection unit 100.

[0055] The drive unit 70 is capable of independently driving plungers 55, 56, and 57. In the first embodiment, the drive unit 70 includes a drive mechanism 71 capable of driving plunger 55, a drive mechanism 72 capable of driving plunger 56, and a drive mechanism 73 capable of driving plunger 57. The drive mechanisms 71, 72, and 73 are capable of operating independently of each other. The drive unit 70, i.e., the drive mechanisms 71, 72, and 73, is operated by a control device 200. Each of the drive mechanisms 71, 72, and 73 includes, for example, an electric mechanism (e.g., an electric motor) or a pneumatic mechanism (e.g., a cylinder).

[0056] Drive mechanism 71 includes a pressing member 711 capable of contacting and disengaging from plunger 55. Pressing member 711 presses plunger 55 to reduce the capacity of storage compartment 58. Drive mechanism 72 includes a pressing member 712 capable of contacting and disengaging from plunger 56. Pressing member 712 presses plunger 56 to reduce the capacity of storage compartment 59. Drive mechanism 73 includes a pressing member 713 capable of contacting and disengaging from plunger 57. Pressing member 713 presses plunger 57 to reduce the capacity of storage compartment 60. Pressing member 711 is an example of a first pressing member. Pressing member 712 is an example of a second pressing member. Pressing member 713 is an example of a third pressing member.

[0057] Valve pins 61, 62, and 63 are valve components, the distal ends of which are valves (gating valves) that open and close outlets G1, G2, and G3, respectively. Valve pin 61 is an example of a first valve component. Valve pin 62 is an example of a second valve component. Valve pin 63 is an example of a third valve component. Figure 1 As shown, valve pin 61 is a rod-shaped member extending along the axial direction Z1. Valve pin 62 is a rod-shaped member extending along the axial direction Z2. Valve pin 63 is a rod-shaped member extending along the axial direction Z3. Although the axial directions Z1, Z2, and Z3 are parallel to each other in the first embodiment, these directions may intersect each other.

[0058] The distal end of valve pin 61 in the axial direction Z1 opens and closes valve portion 61a of outlet G1 by moving along the axial direction Z1. The distal end of valve pin 62 in the axial direction Z2 opens and closes valve portion 62a of outlet G2 by moving along the axial direction Z2. The distal end of valve pin 63 in the axial direction Z3 opens and closes valve portion of outlet G3 by moving along the axial direction Z3. Valve pins 61, 62, and 63 are driven along the axial directions Z1, Z2, and Z3, respectively, by drive units (not shown). The drive units (not shown) include, for example, electric mechanisms (e.g., electric motors) or pneumatic mechanisms (e.g., cylinders).

[0059] Valve pin 61 is disposed in partial channel 52h, valve pin 62 is disposed in partial channel 52i, and valve pin 63 is disposed in partial channel 52j. The distal end of partial channel 52h in the axial direction Z1 is the discharge port G1. The distal end of partial channel 52i in the axial direction Z2 is the discharge port G2. The distal end of partial channel 52j in the axial direction Z3 is the discharge port G3.

[0060] Partial channel 52h is a channel for supplying molten resin from storage section 58 to cavity CV1. Partial channel 52i is a channel for supplying molten resin from storage section 59 to cavity CV2. Partial channel 52j is a channel for supplying molten resin from storage section 60 to cavity CV3. Injection unit 100 includes heater 41 arranged along partial channel 52h. Figure 1 As shown), heater 42 is arranged along part of channel 52i. Figure 1 (as shown), and heater 43 arranged along part of channel 52j. Figure 1(As shown). Heater 41 is an example of a first heater. Heater 42 is an example of a second heater. Heater 43 is an example of a third heater. Heater 41 is arranged on the outer peripheral surface of a protruding member 91 having a cylindrical shape and defining a partial channel 52h in the limiting portion 52. Heater 42 is arranged on the outer peripheral surface of a protruding member 92 having a cylindrical shape and defining a partial channel 52i in the limiting portion 52. Heater 43 is arranged on the outer peripheral surface of a protruding member 93 having a cylindrical shape and defining a partial channel 52j in the limiting portion 52.

[0061] The positions of the outlets G1, G2, and G3 in the height direction, i.e., the lengths of the partial channels 52h, 52i, and 52j, are set according to the positions of the cavities CV1, CV2, and CV3, i.e., the positions where the molded part will be formed on the workpiece 13. Therefore, the partial channels 52h, 52i, and 52j can be set to different lengths. Consequently, the lengths of the heaters 41, 42, and 43 are set according to the lengths of the partial channels 52h, 52i, and 52j, respectively.

[0062] In the example of the first embodiment, part of channel 52h is longer than part of channel 52i. Therefore, heater 41 is set to be longer than heater 42. In the first embodiment, the length of part of channel 52h is its length in the axial direction Z1, and the length of part of channel 52i is its length in the axial direction Z2. Additionally, in the first embodiment, the length of heater 41 is its length in the axial direction Z1, and the length of heater 42 is its length in the axial direction Z2. When the length of part of channel 52h is L11 and the length of part of channel 52i is L12, L11 > L12 holds. Furthermore, when the length of heater 41 is L21 and the length of heater 42 is L22, L21 > L22 holds.

[0063] The molten resin flowing in partial channels 52h, 52i and 52j and supplied to cavities CV1, CV2 and CV3 is kept at a predetermined temperature by heaters 41, 42 and 43, thus maintaining a good molten state.

[0064] Valve pin 61 includes a valve portion 61b that opens and closes the outlet of the molten resin in partial channel 52x, i.e., opens and closes the outlet 81 of the molten resin in branch channel 52b. Valve pin 62 includes a valve portion 62b that opens and closes the outlet of the molten resin in partial channel 52y, i.e., opens and closes the outlet 82 of the molten resin in branch channel 52c. Valve portion 62b has a substantially the same construction as valve portion 61b. Note that, although not shown in the figure, valve pin 63 includes a valve portion having a similar construction to valve portions 61b and 62b, which opens and closes the outlet 83 of the molten resin in branch channel 52d.

[0065] The construction of the valve portion 62b of valve pin 62 and the valve portion of valve pin 63 is similar to that of the valve portion 61b of valve pin 61; therefore, only valve pin 61b will be described below. Here, valve portion 61a of valve pin 61 is an example of a first valve portion, and valve portion 61b of valve pin 61 is an example of a second valve portion. Valve portion 62a of valve pin 62 is an example of a third valve portion, and valve portion 62b of valve pin 62 is an example of a fourth valve portion.

[0066] Figure 5 This is a perspective view of a portion of the valve pin 61 according to the first embodiment. Figure 6A yes Figure 2 A cross-sectional view of valve section 61b and its vicinity. Figure 6A This shows the state where the valve portion 61a of the valve pin 61 has been moved to the closed position P1 to close the outlet G1. Figure 6B It is along Figure 6A A sectional view of valve section 61b and its vicinity taken by line VIB-VIB. Figure 7A yes Figure 2 A cross-sectional view of valve section 61b and its vicinity. Figure 7A This shows the state where the valve portion 61a of the valve pin 61 has been moved to the open position P2 to open the outlet G1. Figure 7B It is along Figure 7A A sectional view of valve section 61b and its vicinity taken from line VIIB-VIIB.

[0067] The limiting portion 52 includes an inner peripheral surface 155 defining a hole H1 extending along the axial direction Z1. The inner peripheral surface 155 also defines a connecting channel 52k and a partial channel 52h. The connecting channel 52k is a channel connecting the partial channel 52x and the partial channel 52h. A valve pin 61 is inserted into the hole H1 defined by the inner peripheral surface 155 and is movable along the inner peripheral surface 155 in the axial direction Z1. Therefore, the valve portion 61b, which is part of the valve pin 61, can slide in the hole H1 defined by the inner peripheral surface 155 in the axial direction Z1.

[0068] A portion of the hole H1 consists of a partial channel 52h and a connecting channel 52k. Additionally, branch channels 52b and 52e of the partial channel 52x are connected to the hole H1, i.e., connected to the connecting channel 52k, while intersecting with the connecting channel 52k. In the first embodiment, the branch channels 52b and 52e are orthogonally connected to the hole H1, i.e., to the connecting channel 52k. An outlet for the molten resin of the partial channel 52x, i.e., a resin outlet 81 for the molten resin of the branch channel 52b, is provided in the inner peripheral surface 155.

[0069] Valve pin 61 (i.e., valve portions 61a and 61b) can slide in the axial direction Z1 along a direction Z11 moving away from the discharge port G1 and a direction Z12 moving towards the discharge port G1. Direction Z12 is opposite to direction Z11. Because valve pin 61 slides in the axial direction Z1, valve portion 61a can move to a closed position P1 that closes the discharge port G1 and an open position P2 that opens the discharge port G1. Valve portion 61a moves from the closed position P1 to the open position P2 by sliding in direction Z11. In addition, valve portion 61a moves from the open position P2 to the closed position P1 by sliding in direction Z12.

[0070] The valve pin 61 includes a columnar portion 161 extending in the axial direction Z1 and a columnar portion 162 extending in the axial direction Z1. A valve portion 61b is disposed between the columnar portions 161 and 162. The columnar portion 161 is arranged on the outlet G1 side relative to the columnar portion 162 and the valve portion 61b, and when the valve pin 61 moves in the axial direction Z1, the distal end of the columnar portion 161 in the axial direction Z1 opens and closes the outlet G1. That is, the distal end of the columnar portion 161 in the axial direction Z1 serves as a valve portion 61a for opening and closing the outlet G1.

[0071] The columnar portion 162 has a larger diameter than the columnar portion 161. The columnar portion 162 fits into the inner peripheral surface 155 of the limiting portion 52 so that it can slide along the axial direction Z1. That is, the outer peripheral surface 1621 of the columnar portion 162 contacts the inner peripheral surface 155 of the limiting portion 52.

[0072] The columnar portion 161 is arranged so as not to contact the inner peripheral surface 155 of the limiting portion 52, and the space between the inner peripheral surface 155 of the limiting portion 52 and the outer peripheral surface 1611 of the columnar portion 161 serves as a partial channel 52h.

[0073] Valve portion 61b includes a columnar portion 163 having the same diameter as columnar portion 162, and a columnar portion 164 having a smaller diameter than columnar portions 162 and 163. Columnar portions 163 and 164 are arranged between columnar portions 161 and 162. The outer peripheral surface 1631 of columnar portion 163 is a columnar surface and contacts the inner peripheral surface 155 of defining portion 52 so as to allow sliding in the axial direction Z1.

[0074] A columnar portion 164 is arranged between columnar portions 163 and 162. Therefore, an annular groove is defined between columnar portions 162 and 163, and an annular space R1 corresponding to the annular groove is defined between columnar portion 164 and the inner peripheral surface 155 of the limiting portion 52. A groove 1632 extending in the axial direction Z1 is provided on columnar portion 163, such that space R1 and a portion of channel 52h communicate with each other. A space R2 connected to space R1 and a portion of channel 52h is defined between groove 1632 and the inner peripheral surface 155 of the limiting portion 52. The connecting channel 52k includes spaces R1 and R2. Note that the columnar portions 161 to 164 of valve pin 61 may or may not have a hollow shape.

[0075] When the valve part 61a of the valve pin 61 moves to such a position Figure 6A When in the closed position P1, the outer peripheral surface 1631 moves to the position where the outlet 81 of the branch channel 52b is open. As a result, the partial channel 52x is connected to the partial channels 52h and 52e via the connecting channel 52k. At this time, since the outlet G1 is closed by the valve portion 61a of the valve pin 61, the molten resin M1 that has flowed through the branch channel 52b of the partial channel 52x flows into the storage section 58 via the connecting channel 52k and the partial channel 52e, and is thus stored in the storage section 58.

[0076] Additionally, when the valve portion 61a of the valve pin 61 is as follows Figure 7A When the device moves to the open position P2, the space R1, i.e., the connecting channel 52k, shifts relative to the outlet 81 along the direction Z11, and the outer peripheral surface 1631 moves to the position where the outlet 81 of the branch channel 52b is closed. At this time, the discharge port G1 opens, so by moving the plunger 55 to reduce the capacity of the storage section 58, the molten resin M1 stored in the storage section 58 is discharged from the discharge port G1 through the partial channels 52e and 52h.

[0077] In the first embodiment, the branch channel 52b, which is opened and closed by the valve portion 61b, is connected to the hole H1, i.e., to the connecting channel 52k, in a manner that intersects with it. Therefore, the outer peripheral surface 1631 of the valve portion 61b is subjected to pressure from the molten resin M1 remaining in the branch channel 52b, not in the axial direction Z1, but in a direction intersecting the axial direction Z1. The axial direction Z1 is the driving direction of the valve pin 61. Figure 7A In the example, the outer peripheral surface 1631 of the valve portion 61b is subjected to pressure from the molten resin M1 remaining in the branch channel 52b in a direction orthogonal to the axial direction Z1.

[0078] Therefore, the movement of valve pin 61, i.e., valve part 61b, along the axial direction Z1, specifically along the direction Z12, is suppressed by the pressure of the molten resin M1 remaining in the branch channel 52b. As a result, valve part 61a is held in the open position P2 with high precision to open the discharge port G1, and leakage of molten resin M1 from the branch channel 52b to the partial channel 52h at valve part 61b can be suppressed.

[0079] Furthermore, the outer peripheral surface 1631 is a cylindrical surface extending straight along the axial direction Z1, thus it can be easily manufactured with high precision. The inner peripheral surface 155 defining the hole H1 is also a cylindrical surface extending straight along the axial direction Z1, thus it can be easily manufactured with high precision. Therefore, leakage of molten resin between the branch channel 52b and the partial channels 52e, 52h through the gap between the outer peripheral surface 1631 and the inner peripheral surface 155 can be effectively reduced.

[0080] Because the valve section 61b has the above-described structure, the change in the amount of molten resin injected from the outlet G1 into the cavity CV1 relative to the capacity of the cavity CV1 is reduced, and the quality of the molded part to be molded, i.e., the quality of the product, is improved.

[0081] In the manufacturing apparatus 1000 of the first embodiment, the product is manufactured sequentially by repeating the metering step, the injection step, and the cooling step. Note that in these steps, the operation of plungers 56 and 57 is substantially the same as the operation of plunger 55, and the operation of valve pins 62 and 63 is substantially the same as the operation of valve pin 61. Therefore, only the operation of plunger 55 and valve pin 61 will be described below, and the operation of plungers 56 and 57 and valve pins 62 and 63 will be omitted.

[0082] Figure 8 This is a longitudinal sectional view of the injection unit 100 according to the first embodiment. Figure 8 This indicates that the measurement step has been completed.

[0083] Here, before the metering step begins, the control device 200 performs drive control on the valve pin 61 to move valve section 61a to the closed position P1 and valve section 61b to the open position. As a result, valve section 61a closes the discharge port G1, and valve section 61b opens the outlet 81 of the branch channel 52b. Figure 6A The connecting channel 52k of the connecting branch channel 52b and the partial channel 52e shown is formed by the valve section 61b. In addition, during the metering step, the molten resin M1 discharged from the plasticizing section 49 is injected into the storage section 58 through the main channel 52a, the branch channel 52b, the connecting channel 52k and the partial channel 52e.

[0084] Figure 9 This is a longitudinal sectional view of the injection unit 100 according to the first embodiment. Figure 9The state at the start of the injection step is shown. After the injection of molten resin M1 into the storage section 58 is completed, that is, after the metering step is completed, the control device 200 executes the drive control of the valve pin 61 to move valve section 61a to the open position P2 and valve section 61b to the closed position, as shown. Figure 9 As shown. As a result, valve 61a opens outlet G1, and valve 61b closes outlet 81 of branch channel 52b.

[0085] Figure 10 This is a longitudinal sectional view of the injection unit 100 according to the first embodiment. Figure 10 The state after the injection step is shown. During the injection step, the control device 200 controls the drive mechanism 71 to cause the plunger 55 to eject the molten resin M1 injected into the reservoir 58. That is, the control device 200 drives the plunger 55 to move, thereby reducing the capacity of the reservoir 58. By moving the plunger 55 in this manner, the molten resin M1 stored in the reservoir 58 is injected from the outlet G1 into the cavity CV1 via partial channels 52e and 52h.

[0086] At this time, valve 61b closes branch channel 52b, thus suppressing the backflow of molten resin M1 into branch channel 52b, i.e., into plasticizing section 49. Therefore, molten resin M1 injected into storage section 58 and metered to a predetermined amount can be stably discharged from outlet G1.

[0087] Furthermore, the partial channel 52e has a shape in which the cross-sectional area increases in a stepped manner towards the plunger 55, and in a shape in which the cross-sectional area decreases in a stepped manner towards the outlet G1. As described above, compared to the case where the channel narrows abruptly, when the plunger 55 is driven, the driving force of the plunger is effectively transmitted to the molten resin M1, and the pressure loss of the molten resin M1 is reduced in the section from the partial channel 52e to the outlet G1. Therefore, the molten resin M1 can be injected into the cavity CV1 at the desired pressure.

[0088] After the injection step is completed, a metering step for metering the amount of molten resin to be injected next is performed in parallel with the cooling step for cooling the molten resin M1 injected into the cavity CV1.

[0089] Figure 11 This is a longitudinal sectional view of the injection unit 100 according to the first embodiment. Figure 11 The status of the initial measurement step is shown. For example... Figure 11As shown, the control device 200 executes the drive control of the valve pin 61 to move the valve part 61a to the closed position P1 and the valve part 61b to the open position. As a result, the valve part 61a closes the discharge port G1, and the valve part 61b opens the outlet 81 of the branch channel 52b. The connecting channel 52k connecting the branch channel 52b and the partial channel 52e is formed by the valve part 61b. In addition, the control device 200 controls the drive mechanism 71 and causes the pressing member 711 to retract to the position away from the plunger 55.

[0090] Furthermore, during the metering step, the control device 200 rotates the screw 50 of the plasticizing section 49. As a result, molten resin is discharged from the plasticizing section 49. The molten resin M1 discharged from the plasticizing section 49 is injected into the storage section 58 through the main channel 52a, branch channel 52b, connecting channel 52k, and partial channel 52e. At this time, the plunger 55 is pressed by the molten resin M1 supplied to the storage section 58, and thus moves closer to the pressing member 711.

[0091] Figure 12 This is a longitudinal sectional view of the injection unit 100 according to the first embodiment. Figure 12 This indicates that the measurement step has been completed. (Example) Figure 12 As shown, the plunger 55 is pressed by the molten resin M1, and thus moves backward to contact the pressing member 711. That is, the plunger 55 contacts the pressing member 711 when the molten resin M1 in the storage section 58 reaches a predetermined volume. The predetermined volume is equal to the capacity of the cavity CV1. Upon detecting that the plunger 55 is in contact with the pressing member 711, the control device 200 stops the rotation of the screw 50 of the plasticizing section 49 and completes the metering.

[0092] In the first embodiment, the plunger 55 is separated from the pressing member 711 of the drive mechanism 71. Therefore, it is not necessary to forcibly retract the plunger 55 during the metering step. That is, the plunger 55 retracts due to the pressing force of the molten resin M1. If the plunger is forcibly retracted, the capacity of the reservoir may suddenly increase, resulting in a sudden pressure change in the molten resin within the reservoir, and changes in the mass of the molten resin in the reservoir, such as air mixing into the molten resin. In the molded article formed from the molten resin affected by the sudden pressure change, molding defects such as voids and silver streaks may occur.

[0093] Conversely, in the first embodiment, since the plunger 55 and the drive mechanism 71 are separated, the plunger 55 can be moved back by being pushed back by the molten resin M1 after the pressing member 711 of the drive mechanism 71 retracts. As a result, sudden pressure changes in the molten resin M1 within the reservoir 58 can be reduced. Therefore, mass changes in the molten resin M1 or mixing of air in the molten resin M1 can be reduced, thus enabling the manufacture of molded articles of good quality. Furthermore, it is preferable that either or both of the contact portion of the plunger 55 and the contact portion of the pressing member 711 are spherical surfaces. As a result, even if the pressing member 711 moves forward in a slightly tilted state, the plunger 55 can move forward while correcting the tilt of the pressing member 711 in a manner that follows the inner wall of the cylinder. Therefore, the occurrence of the plunger 55 being stuck by the inner wall of the cylinder, i.e., jamming, can be reduced.

[0094] Note that while it is preferred to separate the plunger 55 from the drive mechanism 71, the construction is not limited to this, and the plunger 55 and the drive mechanism 71 may also be connected. Additionally, the plunger 55 may include a head that contacts the molten resin and a shaft portion separate from the head, and the shaft portion may be connected to the drive mechanism 71.

[0095] Note that the construction and operation of the components associated with resin channel 522, and the components associated with resin channel 523, are substantially the same as those associated with resin channel 521. Valve pin 61, plunger 55, and drive mechanism 71 are components associated with resin channel 521. Valve pin 62, plunger 56, and drive mechanism 72 are components associated with resin channel 522. Valve pin 63, plunger 57, and drive mechanism 73 are components associated with resin channel 523. Therefore, molten resin is stably discharged from outlets G1, G2, and G3.

[0096] Since plungers 55, 56, and 57 are driven independently of each other by drive unit 70, their position control can be performed independently, and the capacity of storage units 58, 59, and 60 can be adjusted independently. As a result, the injection volume of resin can be adjusted for each discharge port G1, G2, and G3. In addition, plungers 55, 56, and 57 can stably discharge molten resin without being affected by each other's injection operations.

[0097] Furthermore, the backflow of molten resin to the plasticizing section 49 can be effectively suppressed at valve pins 61, 62, and 63. In addition, the interaction between the opening and closing timings of valve pins 61, 62, and 63 can be suppressed, thus enabling the injection of molten resin in a stable quantity.

[0098] Here, as Figure 4As shown, a pressure sensor 64 for detecting the resin pressure in partial channel 52e is provided in partial channel 52e, and a pressure sensor 65 for detecting the resin pressure in partial channel 52f is provided in partial channel 52f. Pressure sensor 64 is an example of a first pressure sensor. Pressure sensor 65 is an example of a second pressure sensor. Note that a pressure sensor (not shown) for detecting the resin pressure in partial channel 52g is provided in partial channel 52g. A pressure sensor (not shown) is an example of a third pressure sensor. These pressure sensors are preferably arranged at locations with smaller cross-sectional areas within the channels.

[0099] The control device 200 controls the drive unit 70 to drive the plunger 55 based on the pressure value detected by the pressure sensor 64. Similarly, the control device 200 controls the drive unit 70 to drive the plunger 56 based on the pressure value detected by the pressure sensor 65. Similarly, the control device 200 controls the drive unit 70 to drive the plunger 57 based on the pressure value detected by a pressure sensor (not shown).

[0100] In the first embodiment, the lengths of branch channels 52b, 52c, and 52d are different from each other. For example, Figure 4 The lengths L1 and L2 shown are different from each other. Therefore, it can be assumed that the timing of the molten resin being injected into the reservoirs 58, 59, and 60 is also different. Therefore, according to the first embodiment, by measuring the pressure near the reservoirs 58, 59, and 60, injection conditions corresponding to the pressure values ​​can be set. In addition, by measuring the injection pressure when injection is performed using each plunger 55, 56, and 57, the driving conditions of the plungers 55, 56, and 57 can be set so that the injection pressures are equal. In the first embodiment, since the plungers 55, 56, and 57 and the drive mechanisms 71, 72, and 73 are provided corresponding to the discharge ports G1, G2, and G3, the driving conditions of the plungers 55, 56, and 57 can be set independently. Therefore, the injection states of the molten resin injected from the discharge ports G1, G2, and G3 can be matched with each other.

[0101] In a first embodiment, cavities CV1, CV2, and CV3 are defined between the workpiece 13 and the molds 21, 22, and 23 by contacting molds 21, 22, and 23 with the workpiece 13 molded from resin. Mold 21 is an example of a first mold. Mold 22 is an example of a second mold. Mold 23 is an example of a third mold. By injecting molten resin into the cavities CV1, CV2, and CV3, three molded articles are externally molded onto the workpiece 13, thereby manufacturing a product.

[0102] Figure 13 and 14 This is an explanatory diagram of product 10 according to the first embodiment. Figure 13This is a floor plan of product 10. Figure 14 This is a cross-sectional view of product 10. In the first embodiment, components 14, 15, and 16, as resin molded articles, are externally molded onto workpiece 13 to manufacture product 10. That is, product 10 is manufactured by adding components 14, 15, and 16 to workpiece 13. Component 14 is a molded article molded in cavity CV1, component 15 is a molded article molded in cavity CV2, and component 16 is a molded article molded in cavity CV3. Components 14, 15, and 16 are, for example, sealing components for sealing powder.

[0103] Component 14 has a different volume than components 15 and 16. Therefore, the cavity CV1 of the mold 21 used to mold component 14 has a different capacity than the cavity CV2 of the mold 22 used to mold component 15. Similarly, the cavity CV1 of the mold 21 used to mold component 14 has a different capacity than the cavity CV3 of the mold 23 used to mold component 16.

[0104] The resin material used for molding is preferably a resin suitable for use in sealing components and that can be molded by injection molding, such as a thermoplastic elastomer resin.

[0105] In the first embodiment, the positions of plungers 55, 56, and 57 can be controlled independently, and the capacities of storage sections 58, 59, and 60 can be changed individually. That is, the resin storage amount in storage sections 58, 59, and 60 can be adjusted individually. As a result, molten resin can be stably injected from each of the discharge ports G1, G2, and G3, and the quality of product 10 can be improved.

[0106] A manufacturing method for externally inserting molded components 14, 15, and 16 onto workpiece 13 will be briefly described. First, workpiece 13 is attached to... Figure 1 The retaining member 30 shown. Figure 8 The molds 21, 22, and 23 shown are arranged on the retaining member 30.

[0107] A transport table (not shown) on which the retaining member 30 is placed is movable in both the mold clamping direction and the mold opening direction. When the transport table moves in the mold clamping direction, the mold is clamped. Due to the mold clamping, discharge ports G1, G2, and G3 are connected to cavities CV1, CV2, and CV3.

[0108] After the mold is clamped, during the injection step, the control device 200 moves valve pins 61, 62, and 63 to open outlets G1, G2, and G3. Then, the control device 200 moves plungers 55, 56, and 57 to reduce the capacity of storage sections 58, 59, and 60. As a result, the molten resin injected into storage sections 58, 59, and 60 is injected from outlets G1, G2, and G3 into cavities CV1, CV2, and CV3.

[0109] In the metering step, control device 200 moves valve pins 61, 62, and 63 to close outlets G1, G2, and G3. Furthermore, control device 200 retracts pressing members 711, 712, and 713 by a predetermined stroke based on the capacity of cavities CV1, CV2, and CV3. When molten resin is supplied from plasticizing section 49 to storage sections 58, 59, and 60, plungers 55, 56, and 57 retract by being pressed by the molten resin. When the capacity of storage sections 58, 59, and 60 reaches the capacity of cavities CV1, CV2, and CV3, plungers 55, 56, and 57 contact pressing members 711, 712, and 713. As a result, metering of the molten resin to be injected in the next injection step is completed.

[0110] In addition, following the injection step described above, a cooling step is performed in parallel with the metering step to cool and solidify the molten resin injected into cavities CV1, CV2, and CV3. During the metering step, outlets G1, G2, and G3 are closed, and the mold is opened in this state to remove the product 10, on which components 14, 15, and 16 are formed. By repeating the above operations, the product 10 is manufactured sequentially and efficiently. Furthermore, since the molten resin can be stably injected into cavities CV1, CV2, and CV3, the quality of the manufactured product 10 can be improved.

[0111] Second Embodiment

[0112] A second embodiment will be described. In the second embodiment, elements that are substantially the same as those in the first embodiment will be simplified or omitted. Figure 15 This is a perspective view of a manufacturing system 2000 according to a second embodiment. In the second embodiment, the manufacturing system 2000 will be described as including a plurality of manufacturing apparatuses.

[0113] Manufacturing system 2000 includes manufacturing apparatus 1000A, manufacturing apparatus 1000B, and manufacturing apparatus 1000 as described in the first embodiment. Similar to manufacturing apparatus 1000, manufacturing apparatus 1000A includes multiple resin channels and multiple plungers corresponding to multiple storage sections. For example, manufacturing apparatus 1000A includes two resin channels and two plungers corresponding to two storage sections. Each of the two resin channels has a discharge port. Note that manufacturing apparatus 1000B includes one resin channel and one plunger corresponding to one storage section. That is, manufacturing system 2000 includes two manufacturing apparatuses with multiple plungers each.

[0114] Manufacturing apparatus 1000A includes a resin supply unit 46A, a plasticizing unit 49A, a limiting unit 552A, and a drive unit 70A. Manufacturing apparatus 1000B includes a resin supply unit 46B, a plasticizing unit 49B, a limiting unit 552B, and a drive unit 70B. The drive unit 70A is capable of driving two plungers included in manufacturing apparatus 1000A individually or in a coordinated manner. The drive unit 70B is capable of driving one plunger included in manufacturing apparatus 1000B.

[0115] Note that although the illustrations are omitted, the manufacturing system 2000 includes control devices corresponding to manufacturing apparatus 1000, manufacturing apparatus 1000A, and manufacturing apparatus 1000B. These control devices constitute a control system. The control system can be composed of one or more computers.

[0116] Figure 16 This is an explanatory diagram of product 10A of the second embodiment. Figure 16 This is a plan view of product 10A. Manufacturing apparatus 1000 molds components 14, 15, and 16; manufacturing apparatus 1000A molds component 17; and manufacturing apparatus 1000B molds component 18. Component 17 is an elongated component and is formed by injecting molten resin into a cavity connected to multiple outlets in manufacturing apparatus 1000A. Components 17 and 18 can be molded from resin materials different from those used for components 14, 15, and 16.

[0117] As described above, in the manufacturing apparatus 1000A, the stroke amount of the multiple plungers can be appropriately set according to the shape of the component 17 and the flow characteristics of the resin when molding the component 17, thus enabling stable injection of molten resin. As a result, the quality of the product 10A to be manufactured is improved.

[0118] Third Embodiment

[0119] A third embodiment will be described. In the third embodiment, elements that are substantially the same as those in the first embodiment will be simplified or omitted. Figure 17 This is a plan view of a part of the manufacturing apparatus according to the third embodiment.

[0120] The manufacturing apparatus of the third embodiment includes three plungers 155C, 156C, and 157C, and a drive unit 70C. These three plungers are configured to inject resin branching from the plasticizing section 49 at the defining section 52. The drive unit 70C includes a drive mechanism 171C that drives plungers 155C and 157C in a linked manner, and a drive mechanism 172C that drives plunger 156C independently of plungers 155C and 157C. Both plungers 155C and 157C are driven by drive mechanism 171C.

[0121] If the molten resin injected into the two cavities through the two plungers 155C and 157C has an equal volume, then the two plungers 155C and 157C can be driven by a single drive mechanism 171C.

[0122] In the example of the third embodiment, the volume of molten resin injected into the cavity through plunger 156C is different from the volume of molten resin injected into each of the two cavities through two plungers 155C and 157C. In this case, plunger 156C can be configured to be driven by a drive mechanism 172C that is different from drive mechanism 171C.

[0123] As described above, the stroke of each of the plungers 155C, 156C, and 157C can be appropriately set by taking into account the shape of the molded article to be molded and the flow characteristics of the molten resin. Furthermore, the molten resin injected into the reservoir corresponding to each of the plungers 155C and 157C can be injected stably by means of a constant stroke.

[0124] Note that when it is necessary to change the injection volume between plungers 155C and 157C, the injection volume can be adjusted by arranging a spacer between plunger 155C or 157C and drive mechanism 171C. For example, if metering is performed with a spacer arranged between plunger 155C and drive mechanism 171C and the spacer is removed during injection, the injection volume between plungers 155C and 157C will change. Alternatively, for example, if metering is performed without a spacer arranged between plunger 157C and drive mechanism 171C and injection is performed with a spacer arranged between plunger 157C and drive mechanism 171C, the injection volume between plungers 155C and 157C will change.

[0125] Fourth embodiment

[0126] A fourth embodiment will be described. In the fourth embodiment, elements that are substantially the same as those in the first embodiment will be simplified or omitted. Figure 18 This is a plan view of a part of the manufacturing apparatus according to the fourth embodiment.

[0127] The manufacturing apparatus of the fourth embodiment includes four plungers 155D, 156D, 157D, and 158D, and a drive unit 70D. These four plungers are configured to inject resin branching from the plasticizing section 49 at the defining section 52. The drive unit 70D includes a drive mechanism 171D that drives plungers 155D and 157D in a linked manner, and a drive mechanism 172D that drives plungers 156D and 158D in a linked manner. Drive mechanism 171D drives plungers 155D and 157D independently of plungers 156D and 158D. Drive mechanism 172D drives plungers 156D and 158D independently of plungers 155D and 157D. Plungers 155D and 157D are both driven by drive mechanism 171D, and plungers 156D and 158D are both driven by drive mechanism 172D.

[0128] If the molten resin injected into the two cavities through the two plungers 155D and 157D has an equal volume, then the two plungers 155D and 157D can be driven by a single drive mechanism 171D.

[0129] If the molten resin is injected into the two cavities with equal capacity, the two plungers 156D and 158D can be driven by a single drive mechanism 172D.

[0130] In the example of the fourth embodiment, the volume of molten resin injected into each of the two cavities via plungers 156D and 158D is different from the volume of molten resin injected into each of the two cavities via plungers 155D and 157D. In this case, plungers 156D and 158D can be configured to be driven by a drive mechanism 172D that is different from drive mechanism 171D.

[0131] As described above, the stroke of each of the plungers 155D, 156D, 157D, and 158D can be appropriately set considering the shape of the molded article and the flow characteristics of the molten resin. Furthermore, the molten resin injected into the reservoir corresponding to each of the plungers 155D and 157D can be injected stably with a constant stroke. Additionally, the molten resin injected into the reservoir corresponding to each of the plungers 156D and 158D can be injected stably with a constant stroke.

[0132] Note that if it is necessary to change the injection volume between plungers 155D and 157D, the injection volume can be adjusted by arranging a spacer between plunger 155D or 157D and drive mechanism 171D.

[0133] Note that if it is necessary to change the injection volume between plungers 156D and 158D, the injection volume can be adjusted by arranging a spacer between plunger 156D or 158D and drive mechanism 172D.

[0134] Fifth embodiment

[0135] A fifth embodiment will be described. In the fifth embodiment, elements that are substantially the same as those in the first embodiment will be simplified or omitted. Figure 19 This is a plan view of a part of the manufacturing apparatus according to the fifth embodiment.

[0136] The manufacturing apparatus of the fifth embodiment includes three plungers 155E, 156E, and 157E, and a drive unit 70E. These three plungers are configured to inject resin that is branched off from the plasticizing portion at the defining portion. The drive unit 70E is a drive mechanism that drives the plungers 155E, 156E, and 157E in a linked manner. All three plungers 155E, 156E, and 157E are driven by the drive unit 70E.

[0137] If the molten resin injected into the three cavities through the three plungers 155E to 157E has an equal volume, then the three plungers 155E to 157E can be driven by a single drive unit 70E.

[0138] As described above, the stroke of each of the plungers 155E to 157E can be appropriately set by taking into account the shape of the molded article to be molded and the flow characteristics of the molten resin. Furthermore, the molten resin injected into the reservoir corresponding to each of the plungers 155E to 157E can be injected stably by means of a constant stroke.

[0139] Note that if it is necessary to change the injection volume between plungers 155E and 157E, the injection volume can be adjusted by arranging a spacer between any plunger and the drive unit 70E.

[0140] Sixth Embodiment

[0141] A sixth embodiment will be described. In the sixth embodiment, elements that are substantially the same as those in the first embodiment will be simplified or omitted. Figure 20 This is an explanatory diagram of the two resin channels 521F and 522F of the manufacturing apparatus according to the sixth embodiment. The construction of the resin channels in the sixth embodiment differs from that in the first embodiment.

[0142] The manufacturing apparatus of the sixth embodiment includes a plasticizing section 49, a defining section defining two resin channels 521F and 522F, and two plungers 55F and 56F. The resin channels 521F and 522F do not have a main channel shared between them and are configured to branch directly from the supply port S1 connected to the plasticizing section 49.

[0143] Resin channel 521F is an example of a first resin channel connecting outlet G1 and supply port S1 connected to plasticizing section 49. Resin channel 522F is an example of a second resin channel connecting outlet G2 and supply port S1 connected to plasticizing section 49. Similar to the first embodiment, outlet G1 is connected to cavity CV1, and outlet G2 is connected to cavity CV2. Plunger 55F is an example of a first plunger. Plunger 56F is an example of a second plunger.

[0144] The resin channel 521F includes a storage section 58F, a partial channel 531F, and a partial channel 532F. The storage section 58F is an example of a first storage section and is a space capable of storing molten resin supplied from the supply port S1 connected to the plasticizing section 49. The partial channel 531F is an example of a first partial channel and is a channel connecting the storage section 58F and the supply port S1 connected to the plasticizing section 49. The partial channel 532F is an example of a second partial channel and is a channel connecting the storage section 58F and the discharge port G1.

[0145] The resin channel 522F includes a storage section 59F, a partial channel 533F, and a partial channel 534F. The storage section 59F is an example of a second storage section and is a space capable of storing molten resin supplied from the supply port S1 connected to the plasticizing section 49. The partial channel 533F is an example of a third partial channel and is a channel connecting the storage section 59F and the supply port S1 connected to the plasticizing section 49. The partial channel 534F is an example of a fourth partial channel and is a channel connecting the storage section 59F and the discharge port G2.

[0146] The plunger 55F is movable to reduce the capacity of the reservoir 58F. As the plunger 55F moves to reduce the capacity of the reservoir 58F, the molten resin stored in the reservoir 58F is injected into the cavity CV1 from the outlet G1 through the partial channel 532F.

[0147] The plunger 56F is movable to reduce the capacity of the reservoir 59F. As the plunger 56F moves to reduce the capacity of the reservoir 59F, the molten resin stored in the reservoir 59 is injected into the cavity CV2 from the outlet G2 via the partial channel 534F.

[0148] Similarly, in the construction of the resin channels 521F and 522F described above, similar to the first embodiment, molten resin can be stably injected from each of the outlets G1 and G2, thereby improving the quality of the product to be manufactured.

[0149] As stated above, the quality of the product to be manufactured is improved according to this disclosure.

[0150] This disclosure is not limited to the embodiments described above, and the embodiments can be modified in many ways within the technical concept of this disclosure. Furthermore, the effects described in the embodiments are merely an enumeration of the most preferred effects obtainable from the embodiments of this disclosure, and the effects of the embodiments of this disclosure are not limited to those described in the embodiments.

[0151] For example, the manufacturing apparatus can be configured such that multiple outlets are connected to multiple cavities, or multiple outlets are connected to a single cavity. The multiple cavities can be defined by a single mold, or they can be defined by multiple molds respectively. Furthermore, a portion of each of the multiple cavities, or a portion of a single cavity, can be defined by a workpiece.

[0152] Furthermore, the disclosure in this specification includes not only what is described herein, but also all matters that can be understood from this specification and its accompanying drawings. Moreover, the disclosure in this specification includes the complement of the concepts described herein. Therefore, if this specification contains a description indicating, for example, "A is B," then even if the description indicating "A is not B" is omitted, this specification can still be said to disclose a description indicating "A is not B." This is because the presence of a description indicating "A is B" presupposes the case where "A is not B."

[0153] Although the invention has been described with reference to exemplary embodiments, it should be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims should be given the broadest interpretation in order to cover all such modifications and equivalent structures and functions.

Claims

1. A manufacturing apparatus, comprising: The limiting section is configured to limit (i) a supply port through which molten resin is supplied, (ii) a discharge port through which molten resin is discharged, and (iii) a resin channel connecting the supply port and the discharge port. The resin channel includes a storage section configured to store molten resin, a first part channel connecting the supply port and the storage section, a second part channel connecting the storage section and the discharge port, a relay channel connecting the first part channel and the storage section and connecting the storage section and the second part channel, and a connecting channel connecting the first part channel and the second part channel. A plunger that can move to change the capacity of the reservoir and is configured to discharge molten resin stored in the reservoir from the outlet by moving to reduce the capacity of the reservoir. and A valve component, which is disposed in the connecting channel and the second part channel and is movable along the channel direction of the second part channel, The first part of the channel and the relay channel are connected to the connecting channel in a cross manner with the connecting channel, and Valve components include: The first valve section is configured to open and close the outlet by moving along the channel direction, and The second valve is configured to open the outlet of the molten resin in the first partial channel when the first valve has been moved to the position of closing the outlet, so that the first partial channel is connected to the relay channel, and to close the outlet of the first partial channel when the first valve has been moved to the position of opening the outlet.

2. The manufacturing apparatus according to claim 1, wherein, The second valve has an outer peripheral surface that contacts the inner peripheral surface of the limiting part in a manner that allows it to slide along the channel direction, and is configured to open and close the outlet of the first part of the channel by moving along the channel direction.

3. A manufacturing apparatus, comprising: The limiting section is configured to limit (i) a supply port through which molten resin is supplied, (ii) a first outlet through which molten resin is discharged, (iii) a second outlet through which molten resin is discharged, (iv) a first resin channel connecting the supply port and the first outlet, and (v) a second resin channel connecting the supply port and the second outlet, the first resin channel including a first storage section configured to store molten resin, and the second resin channel including a second storage section configured to store molten resin; A first plunger is movable to change the capacity of the first reservoir and is configured to discharge molten resin stored in the first reservoir from a first outlet by moving to reduce the capacity of the first reservoir. The second plunger is movable to change the capacity of the second reservoir and is configured to discharge the molten resin stored in the second reservoir from the second outlet by moving to reduce the capacity of the second reservoir. First valve component; and Second valve component, The first resin channel includes a first part channel connecting the supply port and the first storage section, a second part channel connecting the first storage section and the first discharge port, and a first relay channel connecting the first part channel and the first storage section and connecting the first storage section and the second part channel. The second resin channel includes a third section channel connecting the supply port and the second storage unit, a fourth section channel connecting the second storage unit and the second discharge port, and a second relay channel connecting the third section channel and the second storage unit, and connecting the second storage unit and the fourth section channel. The first plunger moves to reduce the capacity of the first storage section, thereby discharging the molten resin stored in the first storage section from the first outlet via the first relay channel and the second partial channel. The second plunger moves to reduce the capacity of the second storage section, thereby discharging the molten resin stored in the second storage section from the second outlet via the second relay channel and the fourth section channel. The first valve component includes a first valve section and a second valve section. The first valve section is configured to open and close a first outlet when the first valve component moves. The second valve section is configured to open the outlet of molten resin in a first partial channel to connect the first partial channel with a first relay channel when the first valve section has moved to the position of closing the first outlet, and to close the outlet of the first partial channel when the first valve section has moved to the position of opening the first outlet. The second valve component includes a third valve section and a fourth valve section. The third valve section is configured to open and close the second outlet when the second valve component moves. The fourth valve section is configured to open the outlet of the molten resin in the third part of the channel to connect the third part of the channel with the second relay channel when the third valve section has moved to the position of closing the second outlet, and to close the outlet of the third part of the channel when the third valve section has moved to the position of opening the second outlet. The first section of the channel is longer than the third section.

4. The manufacturing apparatus according to claim 3, in, The first relay channel is configured such that its cross-sectional area increases toward the first storage section, and The second relay channel is configured such that its cross-sectional area increases toward the second storage section.

5. The manufacturing apparatus according to claim 3, in, The first resin channel includes a connecting channel that connects the first part of the channel and the second part of the channel. The first valve component is disposed in the connecting channel and the second part channel and is capable of moving along the channel direction of the second part channel. The first section channel and the first relay channel are connected to the connecting channel in a manner that intersects with the connecting channel, and The first valve component opens and closes the first outlet by moving along the channel direction.

6. The manufacturing apparatus according to claim 5, wherein, The second valve section includes an outer peripheral surface that contacts the inner peripheral surface of the limiting section in a manner that allows it to slide along the channel direction, and opens and closes the outlet of the first part of the channel by moving along the channel direction.

7. The manufacturing apparatus according to claim 3, further comprising: The drive unit is configured to drive the first and second plungers separately. A first pressure sensor is configured to detect the resin pressure within a first relay channel; The second pressure sensor is configured to detect the resin pressure within the second relay channel; and The controller is configured to control the drive unit's actuation of the first plunger based on a pressure value detected by a first pressure sensor, and is configured to control the drive unit's actuation of the second plunger based on a pressure value detected by a second pressure sensor.

8. The manufacturing apparatus according to claim 3, wherein, The total length of the first section channel and the first relay channel is different from the total length of the third section channel and the second relay channel.

9. The manufacturing apparatus according to claim 3, further comprising: The first heater is arranged along the second section of the channel; and The second heater is arranged along the fourth section of the channel. The second section of the channel is longer than the fourth section, and The first heater is longer than the second heater.

10. The manufacturing apparatus according to claim 3, in, The first and third sections of the channel are each connected to the main channel shared by the first and second resin channels, and are also connected to the supply port. The first part of the channel includes a first branch channel that branches off from the main channel in a manner that is not linearly connected to the main channel, and The third channel includes a second branch channel that branches off from the main channel in a manner that is not linearly connected to the main channel.

11. The manufacturing apparatus of claim 3, further comprising a drive unit configured to drive the first plunger and the second plunger separately.

12. The manufacturing apparatus according to claim 3, further comprising a drive unit configured to drive the first plunger and the second plunger in a linkage manner.

13. The manufacturing apparatus according to claim 3, in, The limiting section also defines a third resin channel, which includes a third storage section configured to store molten resin and connects a supply port and a third discharge port. The manufacturing apparatus also includes: A third plunger, movable to change the capacity of the third reservoir, and configured to discharge molten resin stored in the third reservoir from a third outlet by moving to reduce the capacity of the third reservoir; and The drive unit is configured to drive the first plunger and the third plunger in a linkage manner.

14. The manufacturing apparatus according to any one of claims 3 to 13, further comprising: The first pressing member is capable of separating from the first plunger and pressing the first plunger to reduce the capacity of the first storage section; and The second pressing member is capable of separating from the second plunger and pressing the second plunger to reduce the capacity of the second storage section.

15. The manufacturing apparatus according to any one of claims 1 to 13, further comprising a plasticizing section connected to the supply port and configured to melt resin.

16. A manufacturing system, comprising: The manufacturing apparatus according to claim 15; and Multiple plasticizing parts, including the plasticizing part.

17. A method of manufacturing a product, the method comprising manufacturing the product by means of a manufacturing apparatus according to any one of claims 1 to 15.

18. The manufacturing method of claim 17, comprising adding resin discharged from the outlet to a single workpiece.

19. A method of manufacturing a product, the method comprising manufacturing the product using a manufacturing apparatus according to any one of claims 3 to 15, wherein, The resin discharged from the first outlet and the resin discharged from the second outlet are added to a single workpiece.

20. A method of manufacturing a product, the method comprising manufacturing the product by means of the manufacturing system according to claim 16.

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