Injection molded control mechanism and like

Abstract

Provided are a control mechanism for injection molding and the like for injection molding of a resin that is substantially uniformly foamed in a mold. A control mechanism for injection molding, which is a control mechanism for injection molding (2) that supplies a mixed material to be mixed to a resin to be injected, is provided with a control unit (3) that acquires supply information (7a) on the basis of resin amount information (6a), the resin amount information 6a includes the resin amount per predetermined time of molten resin filled in front of a screw by the screw 17c of the injection molding machine 10 retreating to a predetermined metering position 19, and the supply information 7a includes the supply speed of the material.

Description

Technical Field

[0001] The present invention relates to a control mechanism for injection molding, etc. Further, the present invention relates to a control mechanism for injection molding, etc., which supplies an inert gas for foaming a resin to an injection molding machine. Background Art

[0002] Patent Document 1 discloses a blowing agent supply system for introducing the blowing agent into a processing system for a polymer foam material. The blowing agent supply system selectively delivers the blowing agent from a supply source to an extruder barrel or through a detour, for example.

[0003] Patent Document 2 discloses an injection molding device that makes the amount (solubility) of a supercritical fluid injected into a molten material and dissolved constant regardless of the screw speed setting value. The injection molding device includes a flow rate resetting unit that multiplies the screw speed setting value by a coefficient set by a coefficient setting unit that sets a coefficient corresponding to the type of material, the type of supercritical fluid, etc., to determine the flow rate setting of the supercritical fluid, and re-sets the flow rate setting unit.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application No. 2003-525780

[0007] Patent Document 2: Japanese Patent Application Publication No. 2003-154526 Summary of the invention

[0008] Problems to be solved by the invention

[0009] There has long been an injection molding system that injects an injection material obtained by mixing an additive with a molten resin into a mold. This system mixes the additive with the resin filled in the cylinder at a constant ratio during the metering action of the injection molding machine. However, the filling speed of the resin fluctuates with changes in the screw speed and the screw retraction speed of the injection molding machine. Therefore, in the filled resin, there is a situation where the proportion of the additives will be locally different. When the injection material with different shades is injected into the mold, it may become one of the reasons for the uneven dispersion of the additives in the molded product.

[0010] For example, in the case of foamed resin, if the ratio of gas added to the resin to be injected varies locally, it may be one of the reasons why the injected resin foams unevenly in the mold. Therefore, considering the reduced strength of the most foamed part, the overall foaming ratio of the injected resin is reduced. This is one of the reasons that hinder the lightweighting of foamed molded products.

[0011] Therefore, the subject of the present invention is to provide a control mechanism for injection molding, which mixes materials to be mixed in a proportion corresponding to the resin to be injected, an injection molding device, an injection molding system, a program for the control mechanism, and an adjustment method for injection molding materials, as well as the manufacture of a molded body in which materials to be mixed in a proportion corresponding to the resin to be injected and a molded body.

[0012] Means for solving problems

[0013] (1) The control mechanism for injection molding of the present invention is a control mechanism for supplying material to be mixed into a filling resin to an injection molding machine, and is characterized in that it comprises a control unit that obtains supply information related to a supply speed of the material based on filling information related to a filling speed of the resin in a metering operation of the injection molding machine.

[0014] "Filling information" refers to information related to the filling flow rate, including the filling flow rate of the resin filled in the cylinder of the injection molding machine, and is a concept that can be converted into the filling flow rate, including the filling amount of the resin within a specified time, the time required to fill the specified amount of resin, etc. For example, here, the flow rate includes mass flow rate and volume flow rate.

[0015] For example, as filling information, when the filling flow rate of the resin is calculated based on the retracting speed of the screw, the filling information includes the retracting speed of the screw, and further includes information related to the retracting speed of the screw, which is a concept that includes quantities that can be converted into the retracting speed of the screw, such as the moving distance of the screw after a specified time has passed, the time taken to move the specified distance, etc.

[0016] Furthermore, for example, when the weight change rate of a hopper of a resin storage unit that supplies resin to an injection molding machine is used as filling information, the filling information includes the weight change rate of the hopper, information related to the weight change rate of the hopper, and is a concept of quantities that can be converted into the weight change rate of the hopper, including the weight change after a specified time, the time taken for a specified weight reduction, and the like.

[0017] The material to be mixed refers to materials such as gas, liquid, solid additive material, etc. that are mixed in the resin.

[0018] The “supply information” refers to the supply flow rate of the materials to be mixed and information related to the supply flow rate, and is a concept that includes quantities that can be converted into the supply flow rate, such as a change in the supply amount after a predetermined time has passed and the time required to supply a predetermined supply amount.

[0019] (2) Preferably, the injection molding control means acquires the filling information at each of one or more times registered in advance, and acquires the supply information for each of the acquired filling information.

[0020] (3) In addition, preferably, a pre-registered initial metering time or an initial retraction amount of the screw is set at the initial stage of the retraction of the screw for metering; and a pre-registered initial supply flow rate for supplying the material is set during the initial metering time or the initial retraction amount.

[0021] (4) Furthermore, preferably, the filling information is information based on position information related to a position of a screw of the injection molding machine.

[0022] The “position information” is information on the position of the screw, for example, and is a concept including the amount of screw retreat, a measured value of the screw position, and an amount convertible thereto.

[0023] (5) In addition, preferably, the material is an inert gas and a supercritical fluid.

[0024] (6) The injection molding device of the present invention is characterized by comprising the above-mentioned control mechanism and a mixed material supply machine, wherein the mixed material supply machine supplies the material based on the supply information from the control mechanism.

[0025] (7) The injection molding system of the present invention is characterized by comprising the above-mentioned injection molding device and an injection molding machine to which the material is supplied from the injection molding device.

[0026] In addition, preferably, the injection molding machine includes a mold. Further preferably, the mold is attached to a mold opening and closing device, and the mold opening and closing device issues a mold closing signal.

[0027] (8) The program of the present invention is a program for a control mechanism that supplies material to be mixed into a filled resin to an injection molding machine, and is characterized in that the program enables a computer to obtain position information including the position of a screw of the injection molding machine that retreats for metering; obtains filling information related to a filling speed of the resin based on the position information; and calculates supply information including a supply speed of the material based on the filling information and predetermined conditions.

[0028] (9) The method for adjusting injection molding materials of the present invention is a method for adjusting injection molding materials, wherein the injection molding material is prepared by supplying a material to be mixed to a filled resin and adjusting the material during a metering action of an injection molding machine, and is characterized in that the adjustment method obtains filling information related to a filling flow rate of the resin at a pre-registered time during the metering action, and supplies the mixture based on supply information related to a supply flow rate corresponding to the filling information.

[0029] (10) The method for producing a molded article of the present invention is characterized in that the injection material is adjusted by the above-mentioned injection material adjustment method and the injection material is injected into a mold.

[0030] (11) The molded body of the present invention is a molded body formed by injecting a molding material into a mold, wherein the molding material is supplied to a filled resin and adjusted during a metering action of an injection molding machine, and is characterized in that the molded body is molded by the following method: filling information related to a filling speed of the resin is obtained at a prescribed time interval during the metering action; supply information related to a supply speed corresponding to each of the filling information is obtained; the injection molding material supplied with the material is adjusted based on the supply information; and the adjusted injection molding material is injection molded.

[0031] Effects of the Invention

[0032] The control mechanism for injection molding, the injection molding device, the injection molding system, the program for the control mechanism, and the method for adjusting the injection molding material of the present invention can obtain an injection molding material that is not easy to produce light or dark in the proportion of the materials to be mixed. In addition, the manufacturing mixing of the molded body and the molded body are not easy to produce light or dark in the proportion of the materials to be mixed. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a graph showing an example of the filling flow rate of the resin and the supply flow rate of the material to be mixed during the metering time.

[0034] Figure 2 This is a functional block diagram showing an example of the functions of the injection system.

[0035] Figure 3 This is a schematic diagram showing an example of the hardware configuration of the control unit.

[0036] Figure 4 This is a flowchart showing one embodiment of the processing flow of the control unit.

[0037] Figure 5 This is a schematic diagram showing an example of the data structure of the setting value table.

[0038] Figure 6 This is a flowchart showing one embodiment of the processing flow of the control unit.

[0039] Figure 7 This is a schematic diagram showing how the cylinder is filled with resin.

[0040] Figure 8 It is a schematic diagram showing how materials to be mixed are provided according to the amount of resin.

[0041] Fig. 9 This is a schematic diagram showing the flow of the mixed material supply machine.

[0042] Fig.10 This is a schematic diagram showing a method for adjusting an injection material and a method for producing a molded body.

[0043] Fig.11 This is a schematic diagram schematically showing the distribution of the expansion ratio of each of a molded article and a conventional molded article. DETAILED DESCRIPTION

[0044] [1. Overview]

[0045] First, use Figure 1 as well as Figure 2 , while comparing with the existing injection molding system, the function of the injection molding system of the present invention is briefly described.

[0046] Figure 1 The cylinder 18a of the injection molding machine 10 is shown (see Figure 2 ) during the metering time (metering time 19), the filling information (filling flow rate) 6a of the filled resin, and the supply information (supply flow rate) 7a of the material body (gas) to be mixed with the resin. As shown in the figure, the filling flow rate 6a of the resin usually fluctuates. There is a tendency that the amount of resin falling from the hopper 18b, the change in the rotation speed of the screw 17c of the injection molding machine, etc. are one of the causes of the fluctuation.

[0047] Figure 1 The upper diagram is a schematic diagram showing a situation of another injection system in which the supply flow rate 7 a of the gas is adjusted to be constant during the metering time 19 , for example.

[0048] For example, in a portion where the filling flow rate 6a is small (refer to Figure 1 The amount of gas supplied is relatively large relative to the amount of resin filled. Therefore, there is a tendency for the molded product to have a portion with expanded bubbles due to the portion A (refer to the schematic diagram of the molded product above the symbol A). On the other hand, at the portion where the filling flow rate 6a is large (refer to Figure 1The amount of gas supplied is small relative to the amount of resin filled. Therefore, there is a tendency for a molded product with broken bubbles to be molded due to the portion B (see the schematic diagram of the molded product above the symbol B).

[0049] In addition, there is a case where the filling of the predetermined amount of resin is completed early due to the fluctuation of the filling flow rate 6a. In this case, since the gas supply flow rate 7a is constant, the filled resin amount cannot be mixed with the gas supply amount of the predetermined ratio. Therefore, the gas supply amount corresponding to the resin amount is fully supplied in advance. For example, it is set to supply the predetermined gas supply amount in full at a larger gas supply flow rate and 70-90% of the resin is filled.

[0050] In addition, at the initial stage of resin filling (the time of symbol D in the figure), there is a tendency that the filling flow rate 6a of the resin is unstable. For example, the filling flow rate 6a of the resin is sometimes fast and sometimes slow, and the amplitude of the flow rate is large. Due to the large amplitude, there is a tendency that it is difficult to mix at the supply flow rate 7a of the gas corresponding to the filling flow rate 6a of the resin.

[0051] Figure 1 The figure below is a schematic diagram showing the situation of the injection molding system of the present invention. As shown in the figure, gas is supplied at a supply flow rate 7a corresponding to the filling flow rate 6a. For example, the supply flow rate 7a is also large at a location where the filling flow rate 6a is large, and the supply flow rate 7a is also small at a location where the filling flow rate 6a is small. In addition, gas is supplied at a supply speed corresponding to the filling speed until the end of the resin filling.

[0052] Therefore, there is a tendency to mold a molded product with substantially uniform bubble diameter (see the graph above the curve). The injection molding system of the present invention that supplies gas (material to be mixed) at a supply flow rate 7a proportional to the filling flow rate 6a is described in detail below.

[0053] 2. Description of each component

[0054] (Injection molding system 1, injection molding device 48)

[0055] use Figure 2 An injection molding system (hereinafter referred to as a system) according to one embodiment of the present invention is described with reference to a functional block diagram of FIG. Figure 2 The system 1 shown includes an injection molding machine 10, a mixing material supply machine 20 for supplying a material to be mixed with a molten resin in the injection molding machine 10, and a control mechanism 2 for injection molding. In the present embodiment, the mixing material supply machine 20 is a gas supply machine for supplying gas. The gas supply machine 20 is provided with a flow control valve 23 for adjusting the supply amount of gas (see Fig. 9). In addition, in the figure, the injection molding machine 10 and the mold 14 are integrated, but the injection molding machine 10 may not include the mold 14 but may be a separate body.

[0056] The control mechanism 2 and a gas supply machine (mixed material supply machine) 20 that supplies the material to be mixed based on the supply flow rate 7a from the control mechanism 2 constitute an injection molding device 48. The gas supply machine 20 will be described in detail later.

[0057] (Control mechanism 2)

[0058] The control mechanism 2 is a mechanism for injection molding, and supplies a gas to be mixed to the resin to be injected. In the present embodiment, nitrogen gas, which is an inert gas in a supercritical fluid state, is used as the gas to be mixed.

[0059] In the present embodiment, for example, the control mechanism 2 includes a control unit 3 , a position acquisition unit 4 , and a storage unit 31 .

[0060] (Control Unit 3)

[0061] The control unit 3 mainly includes, for example, a position acquisition unit 5, a filling acquisition unit 6, and a calculation unit 7. In the present embodiment, the control unit 3 further includes a signal acquisition unit 8 and a setting value acquisition unit 9.

[0062] (Position Acquisition Unit 4)

[0063] In the present embodiment, the position acquisition unit 4 is a rotary encoder. The rotary encoder 4 detects the rotation amount of the motor that moves the screw 17c forward and backward. In the present embodiment, the rotation amount of the motor is acquired as the position information 4a.

[0064] The encoder is a well-known encoder. For example, there are mechanical, optical, magnetic, and electromagnetic induction encoders. The encoder uses a sensor element to detect the rotation as a physical change, and sends the rotation / angle information to the outside as an electrical signal. Based on the obtained encoder signal, at least the rotation amount information of the motor is obtained. In addition, the information of the rotation speed, rotation direction, or rotation position can be obtained.

[0065] In addition, as another position acquisition unit 4, for example, a conventionally known sensor that detects the position of the screw 17c by a change in magnetic force or electric current may be used.

[0066] In addition, a position information unit such as the rotary encoder 4 may be built in the injection molding machine 10 .

[0067] (Position acquisition unit 5)

[0068] The position acquisition unit 5 acquires the position information 4a at a predetermined time interval through the position acquisition unit 4. In the present embodiment, for example, the position information 4a is acquired at a predetermined time interval (sampling time interval) of 0.1 to 0.5 seconds. The position acquisition unit 5 is combined with step S1 (see Figure 6 )correspond.

[0069] (Timing of Acquiring Position Information 4a)

[0070] The timing for acquiring the position information 4a is recorded in advance in the storage unit 31 (see Figure 3 In this embodiment, each sampling time interval 39e (refer to Figure 5 ) obtains position information 4a. For example, the sampling time interval 39e can be set arbitrarily.

[0071] Alternatively, the sampling time (sampling time) 39i may be stored in advance in the storage unit 31, and the position information 4a may be acquired at any time during measurement. The sampling time 39i may include the measurement start time 0.

[0072] (Filling acquisition unit 6)

[0073] The filling acquisition unit 6 acquires the filling flow rate 6a based on the position information 4a including the current position of the screw 17c. In the present embodiment, in addition to the position information 4a, the filling flow rate 6a is acquired based on the condition 5a (described later) including the set value of the cylinder radius and the like. The filling acquisition unit 6 is combined with the step S2 (see Figure 6 )correspond.

[0074] (Calculation unit 7)

[0075] The calculation unit 7 calculates and obtains the gas supply flow rate 7a based on the filling flow rate 6a and the predetermined condition 5b (described later). The obtained supply flow rate 7a is sent to the gas supply device 20. The calculation unit 7 is combined with step S3 (see Figure 6 )correspond.

[0076] (Signal acquisition unit 8, mold closing signal 11a, measuring signal 11a)

[0077] The signal acquisition unit 8 acquires signals from the injection molding machine 10. In the present embodiment, the signals include, for example, a mold closing signal 11a indicating that the mold 14 is being measured and a metering signal 11b indicating that the molten resin is being measured.

[0078] (Closed mode signal 11a)

[0079] The mold closing signal 11a is a signal indicating that the mold 14 is closed. For example, it is a signal indicating that the mold 14 is closed in order to mold the next molded product in the open mold 14. In this embodiment, for example, a signal indicating that the mold 14 starts to close is used. Alternatively, it may be a signal indicating that the closing is completed.

[0080] (Measuring signal 11b)

[0081] The metering signal 11b is a signal indicating the metering time. In the present embodiment, for example, a signal indicating that the rotation direction of the rotary encoder 4 is the direction in which the screw 17c moves backward is used. Alternatively, the backward movement of the screw 17c may be detected from the outside of the cylinder 18a by a sensor or the like as the metering signal 11b.

[0082] (Setting value acquisition unit 9)

[0083] The setting value acquisition unit 9 acquires various setting values. The acquired setting values ​​are stored in a storage unit 31 described later. In the present embodiment, the setting value acquisition unit 9 acquires setting values ​​from an input terminal such as a touch sensor, a smartphone, or a personal computer through manual input by an operator.

[0084] Alternatively, the setting values ​​may be downloaded and acquired from other servers via lines such as the Internet or an intranet.

[0085] (Resin 41)

[0086] Thermoplastic resin materials can be cited as materials for the resin 41. Examples of the thermoplastic resin materials include polylactic acid, polypropylene, polyamide, polyphenylene sulfide, polyimide, polyether ketone, ABS, ASA, and polycarbonate.

[0087] (Material to be mixed 42)

[0088] In this embodiment, nitrogen in a supercritical state is used as the material to be mixed. Gases such as carbon dioxide and inert gas can be used, and these gases in a supercritical state can also be used. In addition, as the mixed material supply machine 20, gas, liquid, and solid can be supplied. As a solid, it is preferably a powdered solid. For example, a physical property improver such as a cross-linking agent, a branching material, a plasticizer, a filler, a crystal nucleating agent, etc. can be used.

[0089] [3. Hardware structure]

[0090] (Hardware Structure of Control Mechanism 2)

[0091] Next, use Figure 3 , the hardware structure of the control mechanism 2 is explained.

[0092] The control mechanism 2 of this embodiment uses, for example, a computer. Figure 3 As shown, the computer includes a CPU 30. In the CPU 30, a memory (storage unit) 31, a connection port 33 for connecting / reading a recording device 32, etc., and a communication circuit 34 for communicating with the outside through a network are connected via a bus 35. In the memory 31, conditions 5a, 5b, a database 39, programs 36a, 36b for processing the system of the present invention, a browser program 37, and an OS 38 (operating system) are recorded.

[0093] In this embodiment, the programs 36a and 36b work in cooperation using the functions of the OS 38 and the browser program 37. In addition, the programs 36a and 36b may operate independently without using the browser program 37 and the OS 38. The conditions 5a and 5b, the programs 36a and 36b, the browser program 37 and the OS 38 are installed in the memory 31 by, for example, downloading via the communication circuit 34 or by the device 32 via the connection port 33.

[0094] In the above hardware structure, for example, the CPU 30 and the programs 36a and 36b are used to implement Figure 2 The functions shown are limited to those described above, but part or all of them may be sequentially controlled using a logic circuit such as a microcomputer or a PLC (Programmable Logic Controller).

[0095] [4. Procedure]

[0096] (Flowchart of initial operation of injection molding system 1)

[0097] Figure 4 This is a flowchart showing one embodiment of the processing flow of a program used in the control mechanism 2. Figure 4 The flowchart shown mainly shows the processing flow of the program 36a in the preparation stage of injection molding, for example, the processing flow during the period from after injection molding to when metering is resumed.

[0098] (R1): CPU 30 of control mechanism 2 (refer to Figure 3 ) When the mold closing signal 11a and the measuring signal 11b are not obtained respectively, a zero value is sent as the flow rate to the flow rate regulating valve 23 (closing valve) described later of the gas supply device 20.

[0099] At this time, the two-way valve 24 on the injection molding machine side and the two-way valve 24b on the atmosphere release side (see Fig. 9 )closure.

[0100] In addition, a signal indicating that the mold 14 is open and a signal indicating that the screw 17c is not retreating can also be obtained.

[0101] (R2): When the mold closing signal 11a is obtained and the measuring signal 11b is not obtained, the start flow rate 39a is sent to the gas supply device 20 (refer to Figure 5 ). The starting flow 39a refers to the flow rate that flows into the flow regulating valve 23 before the gas is supplied to the molten resin. When the gas supply starts, the responsiveness of the flow regulating valve 23 tends to decrease. In order to adjust to an appropriate flow rate, for example, in the present embodiment, a delay of about 1 second occurs. Therefore, a signal 11a indicating that the mold 14 starts to close is obtained, and a specified flow rate is allowed to flow into the flow regulating valve 23 in advance. The mold 14 starts to close, and after the mold 14 is closed and the mold 14 is tightened by hydraulic pressure or the like, metering begins. At the same time as metering begins, the gas flow rate can be adjusted to an appropriate level. In addition, the response delay may be within 1 second or may exceed 1 second.

[0102] In addition, in the present embodiment, the two-way valve 24b on the atmosphere release side is opened (see Fig. 9 ), the gas flowing before supplying the resin is released to the atmosphere. The start-up flow rate 39a is stored in the database 39 of the storage unit 31, for example.

[0103] (Database 39)

[0104] Figure 5 This is a schematic diagram of a database storing set values. Figure 5 The database 39 shown stores predetermined set values. In this embodiment, the set values ​​of the database 39 include a start flow rate 39a, a metering initial flow rate 39b, a metering initial time 39c, a cylinder radius 39d, a sampling time interval 39e, a resin density 39f, a gas addition rate 39g, an initial retreat amount 39h, and a sampling time 39i. These set values ​​will be described in turn in conjunction with related matters.

[0105] return Figure 4 ,

[0106] (R3): Obtain the mold closing signal 11a, obtain the metering signal 11b, and send the metering initial flow rate 39b to the gas supply device 20 within the metering initial time 39c (refer to Figure 5 ).

[0107] The metering initial time 39c refers to the initial stage of metering, that is, the preset time at the initial stage of the screw 17c retreat (see Figure 1Symbol D). In the initial stage of the screw 17c retreating, the back pressure tends to be unstable. If the back pressure is unstable, the retreat amount of the screw 17c, for example, the filling amount of the resin tends to be unstable. In the metering initial time 39c, the metering initial flow rate 39b is set in the flow control valve 23 regardless of the retreat amount of the screw 17c. The metering initial flow rate 39b is an average gas supply flow rate calculated based on the resin amount of one injection amount and the metering time 19.

[0108] For example, the measurement initial time 39c is preferably less than 50% of the entire measurement time 19, and preferably less than or equal to 30 to 20%.

[0109] In addition, the initial retreat amount 39h of the screw 17c can also be set (see Figure 5 ) is used instead of the metering initial time 39c. For example, when the initial retreat amount 39h is set, the screw 17c supplies gas at the metering initial flow rate 39b during the operation of the initial retreat amount 39h.

[0110] For example, the initial retreat amount 39h is preferably less than 50% of the total retreat amount to the metering position 19a, and is preferably 30 to 20% or less.

[0111] (R4): Obtain the mold closing signal 11a, obtain the metering signal 11b, and when the metering initial time 39c is reached or exceeded, send the gas supply flow rate to the gas supply device 20 based on the resin filling flow rate (the resin filling amount at the sampling time interval 39e), and enter the gas supply process (refer to Figure 6 ).

[0112] (Flowchart of metering operation of injection molding system 1)

[0113] Figure 6 This is a flowchart showing one embodiment of the processing flow of a program used in the control mechanism 2. Figure 6 The flowchart shown mainly shows the processing flow of the program 36b for supplying the gas in an amount corresponding to the resin filling amount at each sampling time interval.

[0114] Next, for ease of explanation, add Figure 7 Provide explanation. Figure 7The screw 17c in the metering action is recorded. The mold 14 is arranged at the front end of the cylinder 18a (left side of the figure). The screw 17c retreats in the cylinder 18a (right side of the figure). The resin is filled in the space between the front wall of the cylinder 18a and the front end of the screw 17c. The horizontal axis in the figure is the retreat distance of the screw 17c starting from the front end of the cylinder 18a. The distance L is equivalent to the metering position 19a. The horizontal axis below it represents the time after the screw 17c starts to retreat. The time when the screw 17c reaches the metering position 19a is the metering time 19. Since the retreat speed of the screw 17c fluctuates during metering, the length of the metering time 19 is not necessarily the same for each injection. In addition, there is a similar situation.

[0115] In the figure, the screw 17c is located at a distance L(n+1) at time t(n+1). The two-dot chain line indicates that the screw 17c is located at a distance L(n) at time t(n) before the sampling time interval.

[0116] Wherein, the symbol n is a natural number starting from 0. For example, t(0) is the time when the screw 17c starts to retreat. For example, time t(n+1) represents the (n+1)th sampling time. Time t(n) represents the nth sampling time. ΔT(n+1) is the difference between time t(n+1) and time t(n).

[0117] In addition, the distances L(n+1) and L(n) represent the positions of the screw 17c at time t(n+1) and time (n), respectively. ΔL(n+1) is the difference between L(n+1) and L(n). ΔL(n) corresponds to the amount of retreat of the screw 17c in the sampling time interval ΔT(n).

[0118] (S1): The CPU 30 of the control mechanism 2 (see Figure 3 ) obtains the position information 4a of the retracted screw 17c. Specifically, the distances L(n) and L(n+1) of the screw 17c at time t(n) and time (n+1) are respectively obtained.

[0119] (S2): Obtain filling flow rate 6a. Filling flow rate 6a is calculated based on condition 5a in addition to position information 4a and 4a after time t(n) and t(n+1) seconds. Condition 5a is used to substitute the data from database 39 (refer to Figure 5 ) is composed of a mathematical formula of the selected setting value and position information 4a.

[0120] (Calculation of filling flow rate 6a)

[0121] In this embodiment, for example, from the database 39 (refer to Figure 5) obtains the cylinder radius 39d, sampling time interval 39e and resin density 39f. The volume of the cylinder 18a until the screw 17c retreats by an amount L(n) is calculated based on a pre-registered mathematical formula. The calculated volume of the cylinder 18a is multiplied by the resin density 39f to calculate the amount of resin m(n) measured into the cylinder 18a before the retreat by an amount L(n).

[0122] The resin amount m(n+1) at time t(n+1) is obtained by the same calculation method as above.

[0123] Furthermore, the resin amount m(n) is subtracted from the resin amount m(n+1) to calculate the resin amount ΔM(n+1). The resin amount ΔM(n+1) corresponds to the resin filling amount at the time t(n) to t(n+1).

[0124] Next, the resin amount ΔM(n+1) is divided by the sampling time interval 39e (ΔT(n+1)). Thus, the filling flow rate 6a(n+1) at the time t(n) to t(n+1) is obtained as the filling flow rate 6a (refer to Figure 8 ).

[0125] Figure 8 Indicates the filling flow 6a and the supply flow 7a for each sampling time interval ΔT. The horizontal axis is time t. The vertical axis on the left is the filling flow 6a, and the vertical axis on the right is the supply flow 7a. The double-dotted line schematically indicates the filling flow 6a, and the dotted line schematically indicates the fluctuation of each supply flow 7a. As shown in the figure, the filling flow 6a is calculated for each sampling time interval ΔT. The filling flow 6a(n+1) indicates the filling flow in the sampling time interval ΔT(n+1). The supply flow 7a(n+2) of the gas indicates the supply flow in the sampling time interval ΔT(n+2).

[0126] (S3): Calculate the gas supply flow rate 7a(n+1). The gas supply flow rate 7a(n+2) is calculated based on the filling flow rate 6a(n+1) and the predetermined condition 5b. The condition 5b is used to substitute the data from the database 39 (refer to Figure 5 ) and the mathematical formula of the filling flow rate 6a(n+1). In this embodiment, for example, the gas conversion rate 39f is obtained from the database 39 as the setting value. The filling flow rate 6a(n+1) of the resin is multiplied by the gas conversion rate 39f (refer to Figure 6 ), calculate the gas supply flow rate 7a(n+2) in the next sampling time interval ΔT(n+2).

[0127] (S4): The acquired supply flow rate 7a(n+2) of the gas is sent to the gas supply device 20. At time ΔT(n+2), the gas supply device 20 supplies the gas at the acquired supply flow rate 7a(n+2).

[0128] When the screw 17c retreats to the metering position 19a, the retreat and rotation of the screw 17c are completed. In addition, the gas supply device 20 stops the supply of gas. In this embodiment, for example, in order to stop the supply of gas, the two-way valve 24 (see Fig. 9 ), open the two-way valve 24b on the atmosphere open side.

[0129] (Last sampling time interval ΔT(e))

[0130] The last sampling time interval that reaches the metering time 19 is represented by the symbol ΔT(e). The symbol e means the last. There is a case where the sampling time interval ΔT(e) is shorter than the previous sampling time interval ΔT(e-1). In this embodiment, since the gas is mixed with the supply flow rate 7a based on the filling flow rate 6a of the resin at each sampling time interval ΔT, the gas corresponding to the filling flow rate 6a can be supplied before the screw 17c reaches the metering position 19a.

[0131] (Initial sampling time interval ΔT(1))

[0132] At the initial stage of the screw 17c's retreat, if the back pressure becomes stable, the average gas supply flow rate (the measured initial flow rate 39b) may be supplied as the supply flow rate 7a(1) at the initial sampling time interval ΔT(1). Alternatively, the supply flow rate 7a(2) may be calculated based on the sampling time interval ΔT(2) and the filling flow rate (1) to supply gas.

[0133] (Sampling time interval 39e, sampling time 39i, etc.)

[0134] The sampling time interval 39e may not be constant. For example, the interval may be increased in a stable interval of the back pressure of the screw 17c, and decreased in an unstable interval. In addition, the sampling time 39i may be set independently without setting the sampling time interval 39e to be increased or decreased, and as a result, the sampling time interval 39e may be increased or decreased.

[0135] (Calculation of filling flow rate 6a, etc.)

[0136] The position information 4a used to calculate the filling flow rate 6a can be obtained from any sampling time 39i at two or more points. The sampling times 39i may not be adjacent. In this case, the position information 4a and other data in all the sampling times 39i obtained at the sampling time interval 39e may not be used. Alternatively, the sampling times 39i used for calculation may be recorded in advance in the storage unit 31.

[0137] (Calculation of supply flow rate 7a, etc.)

[0138] The filling flow rate 6a used for calculating the supply flow rate 7a may be obtained from two or more arbitrary filling flow rates 6a. These filling flow rates 6a may not be adjacent.

[0139] [5. Injection molding machine]

[0140] (Injection molding machine 10)

[0141] return Figure 2 An example of an injection molding machine 10 used in the injection molding system 1 of the present invention will be described. The injection molding machine 10 is mounted in the longitudinal direction of a main frame 10a so that a mold opening and closing device 11 and an injection device 12 face each other. The injection molding machine 10 of this embodiment uses an electric motor type mechanism.

[0142] (Mold opening and closing device 11)

[0143] The mold opening and closing device 11 mainly includes a bracket 13, a mold 14 arranged on the bracket 13, and an opening and closing mechanism 15 for closing the bracket 13. The bracket 13 includes a fixed bracket 13a and a movable bracket 13b. The movable bracket 13b is movable by the opening and closing mechanism 15. The opening and closing mechanism 15 includes an opening and closing servo motor 15a fixed to the fixed bracket 13a, a ball screw 15b rotated by the opening and closing servo motor 15a, and a ball screw nut (not shown) fixed to the movable bracket 13b. In this embodiment, the opening and closing mechanism 15 is provided with two upper and lower ones. In addition, one or more than three may be provided. In the case of providing more than three, it is better to provide them at equal intervals.

[0144] By driving the opening and closing servo motor 15a, the ball screw 15b rotates, and the movable bracket 13b moves toward or away from the fixed bracket 13a (front and rear direction). In this embodiment, after the movable bracket 13b moves to close the mold 14, the mold 14 is tightened by a hydraulic mechanism (not shown).

[0145] For example, in the present embodiment, a signal that detects that the opening and closing servo motor 15 a rotates in a direction to close the mold 14 is referred to as the mold closing signal 11 a .

[0146] (Injection molding device 12)

[0147] The injection molding device 12 includes a base 12 a , a screw moving mechanism 16 fixed to the base 12 a , a screw mechanism 17 moved by the screw moving mechanism 16 , and a material supply mechanism 18 that supplies a resin material to the screw mechanism 17 .

[0148] (Screw moving mechanism 16)

[0149] The screw moving mechanism 16 is a mechanism for moving the screw 17c of the screw mechanism 17 in a direction (front-rear direction) toward or away from the mold 14. The screw moving mechanism 16 includes, for example, an injection servo motor 16a provided on the base 12a, a ball screw 16b rotationally driven by the injection servo motor 16a, and a ball screw nut 16c threadedly engaged with the ball screw 16b.

[0150] (Screw mechanism 17)

[0151] The screw mechanism 17 includes a moving portion 17 a that is guided by the base 12 a and is movable in the front-rear direction, a metering servo motor 17 b provided on the moving portion 17 a , and a screw 17 c that is rotated by the metering servo motor 17 b .

[0152] The ball screw 16b is fixed to the moving part 17a. Therefore, the moving part 17a moves in the front-rear direction by the rotation of the injection servo motor 16a. In addition, the moving part 17a is provided with a pressure sensor 17d such as a load cell for detecting the resin pressure applied to the screw 17c.

[0153] (Material supply organization 18)

[0154] The material supply mechanism 18 includes a cylinder 18a provided on the base 12a and a hopper 18b for supplying resin material into the cylinder 18a. A screw 17c is inserted into the cylinder 18a. The screw 17a is freely rotatable in the cylinder 18a and freely movable in the front-rear direction. A heater (not shown) is provided on the outer periphery of the screw 17c.

[0155] (Measuring Operation of Injection Molding Machine 10)

[0156] The metering servo motor 17b is driven to rotate. As the screw 17c rotates, the resin material naturally falls from the hopper 18b into the cylinder 18a. The resin material supplied from the hopper 18b and filled into the cylinder 18a is conveyed to the end side of the screw 17c by the rotation of the screw 17c. During the conveying process, the resin material is melted by the heat generated by the heater and the friction heat and shear heat generated by the rotation of the screw 17c. The molten resin is stored at the end of the cylinder 18a. At this time, the retreat speed of the moving part 17a is controlled by the injection servo motor 16a so that the screw 17c is subjected to a specified resin pressure (back pressure).

[0157] (Injection Operation of Injection Molding Machine 10)

[0158] The stored molten resin advances in the screw 17c and is injected. At this time, the forward speed of the moving part 17a is controlled by the injection servo motor 16a so as to obtain a predetermined resin pressure (injection pressure and holding pressure).

[0159] (Example of Cylinder 18a and Screw 17c)

[0160] The diameter of the cylinder 18a used in this embodiment is 110 mm. The total length of the screw 17c is 550 mm. Of the total length of the screw 17c, the length used in molding is 60.2 to 61.3 mm.

[0161] [6. Gas supply machine]

[0162] (Gas supply machine 20)

[0163] Fig. 9 1 is a schematic diagram showing the flow of a gas supply machine. The gas supply machine 20 shown in the figure mainly includes: a gas tank 21 as a supply source of nitrogen gas, a booster pump 22 for applying pressure to the nitrogen gas supplied from the gas tank 21, a flow regulating valve 23 for adjusting the flow rate of the nitrogen gas obtained from the booster pump 22, and a two-way valve 24 connected to the injection molding machine 10.

[0164] The air tank 21 is provided with a three-way valve 21b via a check valve 21a. The air tank 21 communicates with a flow path on the booster pump 22 side via the three-way valve 21b.

[0165] A pressure reducing valve 25 is provided on the primary side of the boosting pump 22, and a relief valve 26 is provided on the secondary side. Pressure sensors 27, 27 are provided on the primary side and the secondary side of the boosting pump 22 and downstream of the relief valves 26, 26, respectively.

[0166] A pressure reducing valve 25 is provided on the primary side of the flow regulating valve 23, and a back pressure regulating valve 28 is provided on the secondary side. Pressure sensors 27 are provided on the primary side of the flow regulating valve 23 and downstream of the back pressure regulating valve 28 on the secondary side of the flow regulating valve 23, respectively.

[0167] A check valve 24a is provided on the secondary side of the two-way valve 24 connected to the injection molding machine 10. A two-way valve 24b for opening to the atmosphere is provided on the primary side of the two-way valve 24. Filters 29, 29 are provided before the pressure reducing valves 25, 25, respectively.

[0168] Devices such as the booster pump 22, the flow regulating valve 23, the two-way valve 24, the pressure reducing valve 25, the pressure sensor 27, and the back pressure regulating valve 28 are electrically connected to the control mechanism 2. The control mechanism 2 can obtain the detection values ​​and valve opening and closing information obtained from the devices. In addition, the control mechanism 2 can instruct the opening and closing, opening degree, etc. of the valves of the devices.

[0169] (Other Embodiments of Mixed Material Supply Machine 20)

[0170] When the material 42 to be mixed is liquid or solid, a supply port (not shown) communicating with the cylinder 18 a is formed, and the liquid or solid material is supplied from the supply port.

[0171] For example, in the case of liquid, the flow path of the liquid is connected to the supply port, and the liquid material 42 is supplied using a pump or the like that can adjust the flow rate of the liquid.

[0172] For example, in the case of solids, a hopper (see the above-mentioned hopper 18b) mechanism is provided at the supply port. The hopper mechanism is provided with a mechanism for controlling the supply speed of the material 42, such as a supply speed control mechanism such as a screw feeder.

[0173] [7. Method for adjusting injection molding material]

[0174] (Adjustment method 40)

[0175] The adjustment method of the present invention (refer to Fig.10 ) is a method for adjusting the injection material filled in the cylinder 18a of the injection molding machine 10. The injection material 43 is adjusted by supplying the material 42 to be mixed to the filled resin 41.

[0176] The adjustment method 40 shown in the figure obtains the screw retreat speed (filling flow rate) 6a (U1) of the screw 17c of the injection molding machine retreating to the specified metering position 19a at a pre-registered time, obtains the supply information (supply flow rate) 7a (U2) corresponding to the filling flow rate, and supplies the material 42 to be mixed to the resin 41 to be injected (U3). Then, the injection material 43 (U4) is adjusted.

[0177] (Injection material 43)

[0178] The injection material 43 adjusted by the adjustment method 40 is obtained (checked) during the filling process of the resin 41, and the material 42 is mixed with the resin 41 according to the supply information (supply flow rate) 7a corresponding to the filling speed 6a. Therefore, the material 42 can be added at a substantially uniform ratio. In particular, the material 42 can be added at a substantially uniform ratio in the axial direction of the injection material 43 along the screw 17c.

[0179] [8. Manufacturing method]

[0180] (Manufacturing method 44)

[0181] The method for producing the molded article of the present invention (see Fig.10) is a method of injecting the injection molding material 43 adjusted by the above-mentioned adjustment method 40 into the mold 14 (U5). After injection molding, for example, cooling / demolding is performed to obtain a molded body 45 (U6). Since the molded body 45 is molded by injection molding the injection molding material 43, and the injection molding material 43 is a material 42 to be mixed with a resin 41 in a specified ratio, there is a tendency for the material 42 to be uniformly dispersed in the mold 14. Therefore, it is possible to manufacture a molded body 45 in which the material 42 is roughly uniformly dispersed.

[0182] [9. Molded body]

[0183] (Molding body 45)

[0184] The molded body of the present invention is formed by injection molding machine 10 (refer to Figure 2 ) in the metering action, the molding material is injected into the mold 14 to be molded, wherein the molding material is formed by supplying the material 42 to be mixed to the filling resin 41 and adjusting it.

[0185] In the adjustment of the injection molding material 43, the filling flow rate 6a related to the filling speed of the resin 41 is obtained at a predetermined time interval (sampling time interval 39e) in the metering operation. In addition, the supply flow rate 7a related to the supply speed corresponding to each filling flow rate 6a is obtained. Further, the injection molding material 43 supplied with the material 42 is adjusted based on the supply flow rate 7a. Then, the injection molding material 43 in which the material 42 is adjusted to a substantially predetermined ratio is injected into the mold 14 to form a molded body 45.

[0186] For example, a molded body 45 in the case where the material 42 is an inert gas and a supercritical fluid will be described. Fig.11 Graphs schematically showing distributions of expansion ratios of the molded article 45 of the present invention and conventional molded articles 45a and 45b are shown. Fig.11 The molded body 45, the defective molded body 45a, and the conventional molded body 45b shown above are, for example, foamed plate-like members. The x-axis represents the position of the molded body in the x-direction. The molded bodies 45, 45a, and 45b have the same shape. The molded bodies 45 and 45a have the same foaming ratio. The foaming ratio of the molded body 45b is lower than the foaming ratio of the other molded bodies 45 and 45a.

[0187] (Defective molded body 45a)

[0188] The curve directly below the molded bodies 45, 45a, and 45b schematically shows the average expansion ratio of the cross section of the defective molded body 45a at the x position. The straight line 46 shows the expansion ratio required by the design of the molded bodies 45 and 45a. When the expansion ratio exceeds the straight line 46, the expansion ratio becomes higher and the strength decreases. Usually, the molded product is designed not to exceed the straight line 46 at all. Therefore, the defective molded body 45a is not suitable as a product.

[0189] (Conventional molded body 45b)

[0190] The defective molded body 45a has a large amplitude of expansion ratio and the portion with the highest expansion ratio exceeds the straight line 46, so the strength of this portion is lower than the designed strength. In this case, as shown in the curve indicated by the arrow further below, the overall expansion ratio decreases in such a way that the portion with the highest expansion ratio is lower than the straight line 46. Therefore, the weight of the molded body 45b tends to increase.

[0191] (Molding body 45 of the present invention)

[0192] The molded body 45 of the present invention has a small amplitude of the expansion ratio, so the curve 45 indicating the expansion ratio is close to the straight line 46. Therefore, the overall strength is uniform. Moreover, it is lighter than the conventional molded body 45b. In this way, since the molded body 45 is molded by the injection molding material 43 mixed with the gas 42 in a substantially uniform ratio relative to the resin 41, the expansion ratio of the molded body 45 can be made substantially uniform, and the weight can be reduced.

[0193] (Example of Molded Body)

[0194] Next, an embodiment of a molded body of an automobile component will be described. Parameters of an automobile side panel and parameters for manufacturing the side panel are described below.

[0195] · Molding: Side panel

[0196] · Size: 1500mm x 300mm

[0197] · Weight: 351.6g

[0198] · Volume: 493.9cm 3 : is the volume of the molded body 47 (side panel).

[0199] · Resin density: 710mg / cm 3

[0200] · Cylinder diameter: 110mm

[0201] · The gas setting value: 0.3% means that the weight of the injected gas is 0.3% of the resin amount of the molded body 47 .

[0202] · Injection start position: 1 mm, after the screw 17c retreats 1 mm, the gas 42 is injected. This is because the back pressure is unstable in the initial stage of the screw 17c retreating.

[0203] · Measuring correction: 60.2 mm refers to the length used in molding relative to the entire length of the screw 17c.

[0204] · Measuring initial flow rate: 200mg / sec

[0205] · Measuring initial time: 3.0sec

[0206] · Measuring time: about 7.0sec

[0207] · Sampling time interval: 0.3sec

[0208] [10. Others]

[0209] The injection molding machine 10 of the present embodiment uses the injection servo motor 16 a and the metering servo motor 17 b , but both or one of them may be a mechanism using fluid such as hydraulic pressure or pneumatic pressure.

[0210] As the opening and closing mechanism 16 of the mold opening and closing device 12, a mechanism using fluid such as hydraulic pressure or pneumatic pressure may be adopted.

[0211] In the present embodiment, a horizontal injection molding machine is described as an example, but the present invention can also be applied to a vertical injection molding machine.

[0212] The mold closing signal 11 a may also be a signal issued when the mold 14 is closed or when the mold 14 is tightened by hydraulic pressure or the like and is ready for injection molding.

[0213] In step R1, when the gas flow rate is reduced to zero, the two-way valve 24 (see Fig. 9 ) and the two-way valve 24b on the atmosphere open side can be closed or opened.

[0214] In addition, a path open to the atmosphere may be connected to the primary side of the booster pump 22 to serve as a path for returning the gas.

[0215] The startup flow rate 39a may be set to be the same flow rate as the measurement initial flow rate 39b.

[0216] The molded article 45 may be a member of daily necessities, a ship, an airplane, a spacecraft, or the like in addition to an automobile.

[0217] (filling flow, etc.)

[0218] The supply flow rate 7a of the material to be mixed is acquired based on the backward speed of the screw 17c, but the supply flow rate 7a of the material may be acquired based on the weight change of the hopper 18b.

[0219] In addition, the supply flow rate of the material may be calculated by a mathematical formula using the retracting speed of the screw 17c as a function. In this case, the filling flow rate of the resin may not necessarily be used (calculated).

[0220] (Calculation of supply flow rate 7a, etc.)

[0221] The supply flow rate 7a(n+2) in the sampling time interval ΔT(n+2) may be calculated based on the filling flow rates 6a in a plurality of time intervals such as the sampling time intervals ΔT(n) and ΔT(n+1).

[0222] In addition, instead of calculating the filling flow rate 6a, the storage unit 31 (see Figure 3 ) prepares a table consisting of a filling flow rate 6a and a corresponding supply flow rate 7a, and obtains the supply flow rate 7a corresponding to the obtained filling flow rate 6a from the above table.

[0223] [11. Conclusion]

[0224] (1) The control mechanism 2 for injection molding of the present invention is a control mechanism for supplying material to be mixed into a filling resin to an injection molding machine 10, and is characterized in that it comprises a control unit 3 for obtaining supply information 7a related to a material supply speed based on filling information 6a related to a filling speed of the resin in a metering operation of the injection molding machine.

[0225] During the metering time 19 , the filling flow rate 6 a can be checked so that the supply flow rate 7 a corresponding to the filling flow rate 6 a can be obtained.

[0226] (2) This injection molding control mechanism 2 obtains filling information 6a at each of more than one pre-registered time periods and obtains supply information 7a for each obtained filling information 6a. Therefore, the more the number of samples of the filling information 6a is, the more the supply flow rate of the material 42 can be changed or corrected to a more appropriate amount during the metering action.

[0227] (3) In addition, since a pre-registered metering initial time 39c or an initial retreat amount 39h of the screw is set at the initial stage when the screw 17c retreats for metering, and a pre-registered metering initial flow rate 39b of the supply material 42 is set during the metering initial time 39c or the initial retreat amount 39h, appropriate material 42 can be supplied at the initial stage of filling.

[0228] (4) Furthermore, since the filling information 6a is based on the position information 4a regarding the position of the screw 17c of the injection molding machine 10, the filling information 6a can be easily grasped. Therefore, the supply flow rate 7a can be easily controlled.

[0229] (5) Furthermore, since the material 42 is an inert gas and a supercritical fluid, the gas 42 can be added substantially uniformly to the injection material 43. Therefore, there is a tendency for the foaming to be substantially uniform in the mold 14.

[0230] (6) The injection molding device 48 of the present invention is characterized by comprising the above-mentioned control mechanism 2 and a mixed material supply machine 20 for supplying the material 42 based on the supply information 7a from the control mechanism.

[0231] The material 42 can be supplied to the injection molding machine 10 at a supply flow rate 7 a corresponding to the filling flow rate 6 a of the filled resin 41 .

[0232] (7) The injection molding system 1 of the present invention is characterized by comprising the above-mentioned injection molding device 48 and the injection molding machine 10 to which the material 42 is supplied by the injection molding device 48 .

[0233] In the injection material 43, it is possible to prevent the material 42 from having different proportions with respect to the resin 41. The material 43 can be mixed with the resin 41 of the injection material 43 at a substantially uniform ratio.

[0234] (8) The program 36 of the present invention is a program for a control mechanism that supplies material to be mixed into a filling resin to an injection molding machine 10, and is characterized in that the program enables a computer to obtain position information 4a including the position of a screw 17c of the injection molding machine that retreats for metering; obtains filling information 6a related to the filling flow rate of the resin based on the position information 4a; and calculates supply information 7a including the supply flow rate of the material based on the filling information and predetermined conditions 5b.

[0235] During the metering time 19, the filling flow rate 6a can be checked and the supply flow rate 7a can be changed or corrected to correspond to the filling flow rate 6a.

[0236] (9) The method 40 for adjusting the injection molding material of the present invention is a method for adjusting the injection molding material 43, wherein the injection molding material 43 is formed by supplying a material 42 to be mixed to a filled resin 41 and adjusting the material 43 during a metering operation of an injection molding machine 10, and is characterized in that the adjustment method 40 obtains filling information 6a related to the filling flow rate of the resin 41 at a pre-registered time during the metering operation, and supplies the material 42 based on supply information 7a related to the supply flow rate corresponding to the filling information 6a.

[0237] The supply flow rate of the material 42 can be changed or corrected based on the amount of resin filled at the pre-registered time in the metering operation. In the injection material 43, it is possible to prevent the amount of the material 42 from being uneven relative to the resin 41. In particular, it is difficult for the addition rate of the material 42 to be uneven in the axial direction of the injection material 43. The material 42 can be mixed with the resin 41 of the injection material 43 at a substantially uniform ratio.

[0238] (10) The method 44 for producing a molded article of the present invention is characterized in that the injection material 43 is adjusted by the above-mentioned method 40 for adjusting the injection material 43 and the injection material 43 is injected into the mold 14 .

[0239] Since the injection material 43 in which the material 42 is substantially uniformly added to the resin 41 is injected into the mold 14 , the material 42 is easily dispersed substantially uniformly in the mold 14 .

[0240] (11) The molded body 45 of the present invention is a molded body formed by injecting an injection molding material 43 into a mold 14, wherein the injection molding material 43 is formed by supplying a material 42 to be mixed to a filled resin 41 and adjusting it during a metering action of an injection molding machine 10, and is characterized in that the molded body is molded by the following method: obtaining filling information 6a related to a filling speed of the resin 41 at a prescribed time interval 39e during the metering action; obtaining supply information 7a related to a supply speed corresponding to each filling information 6a; adjusting the injection molding material 43 supplied with the material 42 based on the supply information 7a; and injecting the injection molding material 43.

[0241] Since the injection material 43 to which the material 42 is added at a substantially uniform ratio relative to the resin 41 is injected into the mold 14, the material 42 is easily dispersed substantially uniformly in the mold 14. Therefore, there is a tendency to form a molded body 45 in which the material 42 is substantially uniformly dispersed. When the material 42 is an inert gas and a supercritical fluid, the molded body 45 can be foamed substantially uniformly and can be lightweight. In addition, when the material 42 is another added material, since the molded body 45 is a uniform component, the mechanical properties such as strength can be made substantially uniform.

[0242] Explanation of symbols

[0243] 1 injection molding system; 2 control mechanism; 3 control unit; 4 position acquisition unit; 4a position information; 5 position acquisition unit; 5a condition; 5b condition; 6 filling acquisition unit; 6a filling information (filling flow); 7 operation unit; 7a supply information (supply flow); 8 signal acquisition unit; 9 set value acquisition unit; 10 injection molding machine; 11 mold opening and closing device; 11a mold closing signal; 11b metering signal; 12 injection molding device; 12a base; 13 bracket; 13a fixed bracket; 13b movable bracket; 14 mold; 15 opening and closing mechanism; 15a opening and closing servo motor; 15b ball screw; 16 screw moving mechanism; 16a servo motor for injection molding; 16b ball screw; 16c ball screw nut; 17 screw mechanism; 17a moving part; 17b servo motor for metering; 17c screw; 17d pressure sensor; 18 material supply mechanism; 18a cylinder; 18b hopper; 19 metering time; 19a metering position; 20 mixed material supply machine (gas supply device); 21 gas tank; 21a check valve; 21b three-way valve; 22 booster pump; 23 flow control valve; 24 two-way valve (injection molding machine side); 24a check valve; 24b two-way valve (atmosphere open side); 25 pressure reducing valve; 26 relief valve; 27 pressure sensor; 28 back pressure regulating valve; 29 filter; 30 CPU; 31 memory; 32 recording device; 33 connection port; 34 communication circuit; 35 bus; 36a program; 36b program; 37 Browser program; 38 OS; 39 database; 39a start flow; 39b metering initial flow; 39c metering initial time; 39d cylinder radius; 39e sampling time interval; 39f resin density; 39g gas addition rate; 39h initial retreat amount; 39i sampling time; 40 adjustment method; 41 resin; 42 material to be mixed; 43 injection molding material; 44 manufacturing method; 45 molded body; 46 designed foaming ratio; 47 molded body; 48 injection molding device.

Claims

1. The control mechanism of injection molding is a control mechanism for supplying materials to be mixed into the filling resin to the injection molding machine, A control unit is provided for acquiring supply information related to a supply flow rate of the material based on filling information related to a filling flow rate of the resin in a metering operation of the injection molding machine. 2 . The injection molding control mechanism according to claim 1 , wherein the filling information is acquired at each of one or more times registered in advance, and the supply information is acquired for each of the acquired filling information.

3. According to the control mechanism for injection molding according to claim 1 or 2, a pre-registered initial metering time or an initial retreat amount of the screw is set at the initial stage when the screw retreats for metering; and a pre-registered initial supply flow rate for supplying the material is set during the initial metering time or the initial retreat amount. 4 . The injection molding control mechanism according to claim 1 , wherein the filling information is information based on position information related to a position of a screw of the injection molding machine. 5 . The control mechanism for injection molding according to claim 1 , wherein the material is an inert gas and a supercritical fluid.

6. Injection molding device, having: The control mechanism according to any one of claims 1 to 5; A mixed material supply machine supplies the material based on the supply information from the control mechanism.

7. Injection molding system, with: The injection molding device according to claim 6; An injection molding machine to which the material is supplied by the injection molding device. 8 . The injection molding system according to claim 7 , wherein the injection molding machine includes a mold. 9 . The injection molding system according to claim 8 , wherein the mold is mounted to a mold opening and closing device, and the mold opening and closing device issues a mold closing signal.

10. A program for controlling a mechanism for supplying a material to be mixed into a filled resin to an injection molding machine, The program causes the computer to acquire position information including the position of a screw of the injection molding machine that is retreated for metering; acquiring filling information related to a filling flow rate of the resin based on the position information; Based on the filling information and predetermined conditions, supply information including the supply flow rate of the material is calculated.

11. A method for adjusting an injection molding material, wherein: The injection material is prepared by supplying the material to be mixed to the filled resin and adjusting it during the metering action of the injection molding machine. The adjustment method acquires filling information related to the filling flow rate of the resin at a pre-registered time in the metering action; The material is supplied based on supply information associated with a supply flow rate corresponding to the filling information.

12. A method for producing a molded body, comprising adjusting the injection material by the method for adjusting the injection material according to claim 11, and injecting the injection material into the mold.

13. A molded body, which is formed by injecting a molding material into a mold, wherein: The injection molding material is formed by supplying the material to be mixed to the filled resin and adjusting it during the metering action of the injection molding machine, and the molded body is molded by the following method: acquiring filling information related to a filling speed of the resin at predetermined time intervals during the metering operation; acquiring supply information related to a supply speed corresponding to each of the filling information; adjusting the injection molding material to which the material is supplied based on the supply information; The injection molding material is adjusted for injection molding.

Images