Article manufacturing method and manufacturing apparatus

Abstract

An article manufacturing method and manufacturing apparatus capable of removing a molded article from an intermediate mold in an injection molding machine are provided. For this purpose, an intermediate mold disposed between a first mold and a second mold in the injection molding machine is provided with a removal mechanism for removing the molded article.

Description

Technical Field

[0001] The invention relates to an article manufacturing method and manufacturing equipment. Background Art

[0002] Japanese Patent Application Laid-Open No. 2011-230345 discusses a method of providing a rotatable intermediate mold between a first mold and a second mold of an injection molding machine, performing primary molding using the first mold and the intermediate mold to form a molded object, then rotating the intermediate mold 180° with the molded object remaining in the intermediate mold, performing secondary molding using the second mold and the intermediate mold, and then removing the molded object from the second mold.

[0003] Depending on the product, after the primary molding is completed and the mold is opened, it may be necessary to remove the molded item remaining in the intermediate mold. However, in the method of Japanese Patent Application Laid-Open No. 2011-230345, the molded item remaining in the intermediate mold cannot be removed after the mold is opened. Summary of the invention

[0004] Therefore, the present disclosure provides an article manufacturing method and a manufacturing apparatus capable of removing a molded article from an intermediate mold in an injection molding machine.

[0005] One aspect of the present invention provides a method for manufacturing an article, which includes a first molding step of molding using a first mold and an intermediate mold; a rotation step of rotating the intermediate mold; an intermediate removal step of removing the molded article molded in the first molding step from the intermediate mold; and a second molding step of molding using a second mold and an intermediate mold.

[0006] Another aspect of the present invention provides a manufacturing device, which includes: a first mold; a second mold; an intermediate mold, which is arranged between the first mold and the second mold, and the intermediate mold includes a first plurality of surfaces that can be molded with the first mold and a second plurality of surfaces that can be molded with the second mold; and a removal mechanism, which is configured to remove the molded article from the intermediate mold.

[0007] Further features of the present disclosure will become apparent from the following description of exemplary embodiments with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a schematic diagram of an injection molding apparatus;

[0009] FIG. 2A to FIG. 2C is a diagram showing the configuration of a conventional ejector device and an injection molding device;

[0010] Figure 3 is a schematic diagram showing an injection molding device, which is provided with a lifting device at the bottom;

[0011] Figure 4 is a schematic diagram showing an intermediate mold and a lifting device disposed at the bottom of the intermediate mold;

[0012] FIG. 5A to FIG. 5D is a schematic diagram showing a demoulding operation in a lifting device;

[0013] Fig. 6A and Figure 6B is a schematic diagram showing a connection state between an intermediate mold and a lifting device in an injection molding device;

[0014] 7A to 7F is a schematic diagram showing a first molded article and a second molded article in a second step and a third step;

[0015] FIG. 8A to FIG. 8E is a schematic diagram showing an example of removing a molded article from a predetermined position on each surface of an intermediate mold;

[0016] Fig. 9 is a general view showing an inkjet printer;

[0017] FIG. 10A to FIG. 10C is a schematic diagram showing a liquid container;

[0018] FIG. 11A to FIG. 11C is a schematic diagram showing a method of manufacturing a connecting member; and

[0019] FIG. 12A to FIG. 12C is a cross-sectional view showing a first molded article, a second molded article, and a third molded article. DETAILED DESCRIPTION

[0020] Embodiments of the present disclosure will be described below with reference to the accompanying drawings.

[0021] Figure 1 is a schematic diagram of an injection molding apparatus 100 according to the present embodiment. The injection molding apparatus 100 includes a first mold 3 attached to a fixed platen 1 and a second mold 4 attached to a movable platen 2. The second mold 4 is configured to move in the X direction (mold movement direction). The injection molding apparatus 100 also includes an intermediate mold 6, which is arranged between the first mold 3 and the second mold 4 along an LM (linear motion) guide 5 and is configured to rotate around a rotation axis extending in a Z direction substantially orthogonal to the X direction, and the X direction is the movement direction of the second mold 4. The injection molding apparatus 100 also includes an injection unit 7 for the first mold 3 and an injection unit 8 for the second mold 4. The LM guide (support member) 5 extends in the X direction and supports the second mold 4 and the intermediate mold 6. The intermediate mold 6 rotates around an axis orthogonal to the support surface of the LM guide.

[0022] The second mold 4 is configured to move in the X direction together with the intermediate mold 6, and perform mold clamping. In molding, primary molding is first performed by clamping the first mold 3 and the intermediate mold 6 and injecting molten resin from the injection unit 7. Then the mold is opened. At this time, the mold is adjusted so that the first molded article produced by the primary molding remains in the intermediate mold 6.

[0023] The intermediate mold 6 is then rotated 180° so that the first molded article remaining in the intermediate mold 6 is positioned to face the second mold 4. Next, the molds are closed again, primary molding of the second molded article is performed in the first mold 3, and secondary molding of the first molded article is performed in the second mold 4 by injecting molten resin from the injection unit 8.

[0024] Although it has been described that the second mold 4 and the intermediate mold 6 move for mold closing, the configuration is not limited thereto; at least because the first mold 3 and the second mold 4 may instead move toward the intermediate mold 6 .

[0025] FIG. 2A to FIG. 2B is a schematic diagram showing a comparative example, and is a configuration diagram showing a conventional ejector apparatus and an injection molding apparatus including the conventional ejector apparatus in an intermediate mold. Figure 2A and Figure 2B A conventional ejection apparatus is shown before and after removal of a formed article. Figure 2C An injection molding apparatus is shown which includes a conventional ejector apparatus as part of, ie located within, the intermediate mold.

[0026] In order to provide an ejection device in the intermediate mold, a conventional ejection device may be provided in the intermediate mold, such as Figure 2C As shown. Figure 2A and Figure 2B As shown, the conventional ejector device drives a cylinder or the like in a direction to remove the molded article to move the ejector plate in the direction to remove the molded article and remove the molded article. However, in the conventional method of removing the molded article by driving a cylinder or the like in the direction to remove the molded article, the thickness and weight of the intermediate mold may increase, and the size of the injection molding device may increase. Therefore, this embodiment will describe a manufacturing device that can remove the molded article from the intermediate mold while suppressing the size increase of the manufacturing device.

[0027] Figure 3 1 is a schematic diagram showing an injection molding apparatus 100 according to the present embodiment, in which a lifting device 13 is provided in the intermediate mold 6. In the injection molding apparatus 100 according to the present embodiment, the intermediate mold 6 can be rotated 90°. A case where the intermediate mold 6 is rotated 90° will be described. The intermediate mold 6 includes four surfaces for molding and is rotated 90°. The intermediate mold 6 performs molding including rotating to change the surface facing the first mold 3 and the second mold 4.

[0028] In the first step of molding, the injection unit 7 injects molten resin between the first mold 3 and the intermediate mold 6 to mold the molded article (primary molding). Molds of different shapes can be arranged on the same surface to form different types of molded articles. Although it has been explained that the intermediate mold 6 includes four surfaces for molding, the intermediate mold 6 is not limited thereto and may include more surfaces, such as six surfaces.

[0029] After the mold is opened, the process is transferred to the second step by rotating the intermediate mold 6 by 90° while holding (i.e. retaining) the molded article in the intermediate mold 6. Figure 3 The intermediate mold 6 is rotated about an axis extending in the Z direction, but the intermediate mold 6 may also be rotated about a horizontal axis (such as the Y axis). This is basically adopted when the intermediate mold 6 is rotated 180° to perform the process while facing the first mold 3 and the second mold 4, because the second step is performed when the intermediate mold 6 is in a vertical position.

[0030] In the second step, consider using a six-axis robot or the like to insert different types of components (such as filters or rubber parts) into the molded article, or remove the molded article and attach it to the molded article in the adjacent different mold on the same surface. In the case of attachment, in order for the six-axis robot or the like to remove the finished molded article, the molded article needs to be removed from the intermediate mold 6.

[0031] A method of removing the molded article from the intermediate mold 6 (intermediate removal) will be described.

[0032] Figure 4 1 is a schematic diagram showing the intermediate mold 6 and the lifting device 13 provided at the bottom of the intermediate mold 6 . FIG. 5A to FIG. 5D 1 is a schematic diagram showing a demolding operation in a lifting device 13. In the injection molding device 100 according to the present embodiment, the lifting device 13 having a driver (such as a servo motor) abuts against the ejector rod 12 of the intermediate mold 6 to move the ejector rod 12 in a vertical direction (i.e., Z direction) corresponding to the rotation axis direction of the intermediate mold. The ejector rod 12 is connected to the cam plate 14 of the intermediate mold 6, and the cam plate 14 is combined with the ejector plate 16, and the ejector pin 19 is attached to the ejector plate. The cam plate 14 has an inclined portion 50 and is configured so that the ejector plate 16 moves along the inclination of the inclined portion 50. With this structure, the vertical movement of the cam plate 14 caused by the movement of the ejector rod 12 in the vertical direction (i.e., the lifting operation) is converted into the movement of the ejector plate 16 in the horizontal direction (i.e., the Y direction). This enables the ejector pin 19 to move and eject the molded article in the Y direction. In addition, by adjusting the positional relationship between the cam plate 14 and the ejector plate 16, the molded article at a predetermined position can be removed according to the lifting position.

[0033] As described above, since the cam plate 14 has the inclined portion 50 and the vertical movement of the cam plate 14 is converted into the movement of the ejector plate 16 in the horizontal direction (ie, the Y direction), the increase in thickness and weight of the intermediate mold can be suppressed and the size of the injection molding equipment can be reduced.

[0034] Will refer to FIG. 5A to FIG. 5D The demoulding operation, ie, ejection, by the lifting device 13 is described in detail. Figure 5A 17, the second molded article 18, the ejector plate 16, and the cam plate 14. Figure 5B ) moves to position P2 (see Figure 5C ), only the first molded article 17 associated with the upper portion of the cam plate 14 is demoulded. When the cam plate 14 is further moved to position P3 (see Figure 5D ), the second molded article 18 associated with the lower portion of the cam plate 14 is demolded. Similarly, the third molded article and the fourth molded article can be associated with the ejector plate 14; for example, the first molded article and the third molded article can be removed in the second step and attached to the second molded article and the fourth molded article in a subsequent step. In this way, the lifting device is configured to stop at different positions.

[0035] The lifting device 13 may remain connected to the ejector rod 12 of the intermediate mold 6. However, in this case, since the lifting device 13 should rotate with the rotation of the intermediate mold 6, there is a possibility of interference with other components. In addition, since the weight of the intermediate mold 6 increases, the inertial force also increases during the rotational movement, which may cause an increase in the load on the holding portion of the molded article. Therefore, the lifting device 13 is configured to be separated from the ejector rod 12 of the intermediate mold 6.

[0036] Fig. 6A and Figure 6B is a schematic diagram showing a connection state between the intermediate mold 6 and the lifting device 13 in the injection molding device 100; Fig. 6A shows the connection status and Figure 6B The disconnected state is shown. Fig. 6A As shown, the injection molding device 100 is in a connected state when the mold is closed, and is in a disconnected state when the mold is opened. In addition, since it is possible to remove from each surface of the intermediate mold 6, the removal from each surface can be performed by a single lifting device 13, regardless of which surface is positioned in the second step.

[0037] 7A to 7F1 is a schematic diagram showing the first molded article 17 and the second molded article 18 in the second step and the third step. In the second step, the first molded article 17 molded in the first step is removed from the intermediate mold 6 (see FIG. Fig. 7A ) and is attached to the second molded article 18 (see Figure 7B Then, the intermediate mold 6 is rotated 90°. In the third step, the molten resin 23 is injected into the Figure 7C In the illustrated first molded article 17 and second molded article 18 attached to each other. More specifically, by pouring molten resin 23 into a space 22 formed by the first molded article 17 and the second molded article 18, the first molded article 17 and the second molded article 18 are joined together.

[0038] The space 22 is not necessarily formed by a combination of molded articles, and may be formed by a molded article and a mold. FIG. 7D to FIG. 7F In the first molded article 17 and the second molded article 18 formed as shown, a space 22 is formed by the molded article and the mold. By pouring a molten resin 23 into the space 22 formed by the molded article and the mold, the first molded article 17 and the second molded article 18 can be joined together. In addition, so-called two-color molding can be performed in which a molded article obtained by primary molding in the first step is subjected to secondary molding using a different material in the third step.

[0039] Next, the intermediate mold 6 is further rotated 90°. In the fourth step, the molded article is removed from the intermediate mold 6. Also in this step, as in the second step, the molded article at a predetermined position is removed from each surface of the intermediate mold 6 using the lifting device 13 provided at the bottom of the intermediate mold 6. As described above, since the lifting device 13 and the ejector plate 14 are multi-stage, the molded article at a predetermined position on each surface can be removed at any time according to the position.

[0040] FIG. 8A to FIG. 8E 6 is a schematic diagram showing an example of removing a molded article from a predetermined position on each surface of the intermediate mold 6. Fig. 8A As shown, the four surfaces of the intermediate mold 6 are defined as surface A, surface B, surface C, and surface D. Surfaces A to D move as the intermediate mold 6 rotates. That is, for example, surface A advances from the first step via the second and third steps to the fourth step. In addition, each of the surfaces A to D is divided into four equal parts, and various types of molds can be attached to any of the equal parts. FIG. 8B to FIG. 8EIn the figure, "E" indicates the position where the molded article is removed (ejected). Although these steps are performed simultaneously in the injection molding apparatus 100 according to the present embodiment, for the sake of simplicity, the surface A (the upper mold and the lower mold on the right side) will be described in the order of the steps until one molded article is completed, and the description of the surfaces other than the surface A will be omitted.

[0041] In the first step, the surface A is used for preliminary molding to mold a first molded article 17 in the upper right mold in one half of the surface A, and to mold a second molded article 18 in the lower right mold (see FIG. Figure 8B , and the mold shown as "E" in the figure). Thereafter, the intermediate mold 6 is rotated 90 degrees. In the second step, the second molded article 18 in the lower right mold molded in the primary molding is removed (ejected) by raising or lowering the lifting device 13 to a predetermined position, and the second molded article is attached to the first molded article 17 in the upper right mold. Then, the intermediate mold 6 is further rotated 90°. In the third step, molten resin is injected to join (weld) the first molded article 17 and the second molded article 18. Thereafter, the intermediate mold 6 is rotated 90 degrees. In the fourth step, the lifting device 13 moves to a position higher than the position in the second step, and removes the molded article in the upper right mold (the article obtained by joining the first molded article 17 and the second molded article 18).

[0042] Furthermore, by performing the same operation as the right mold also in the upper mold and the lower mold on the left side of the surface A, different types of articles can be molded (in the drawing, the upper mold and the lower mold are reversed left and right).

[0043] Although the method of removing the molded article from the intermediate mold 6 while the intermediate mold 6 is rotated has been described, the present disclosure is also effective when the intermediate mold 6 is not rotated. For example, the present invention is also useful in a case where it is necessary to remove the molded article remaining in the intermediate mold after mold opening in a so-called stack mold, or in a case where the mold is opened while demolding the molded article from the intermediate mold so that the molded article is reliably left in the first mold or the second mold.

[0044] An inkjet printer using a connecting member manufactured by using the injection molding apparatus 100 according to the present embodiment will be described.

[0045] Fig. 9 1 is an overall view showing an inkjet printer 24. In the inkjet printer 24, a liquid container 26 storing liquid and an inkjet print head 25 are communicated with each other through a tube 27 and a hollow needle 28. In the present inkjet printer 24, for example, the injection molding apparatus 100 is useful in producing a connecting member 32 for a connecting portion of the liquid container 26.

[0046] FIG. 10A to FIG. 10C is a schematic diagram showing a liquid container 26; Fig. 10A shows an external view, Fig. 10B shows an exploded perspective view, and Fig. 10C 2 shows a partial enlarged view of the connection part. The liquid container 26 includes a liquid containing portion 29 and a connection member 32. The connection member 32 includes a first molded article 17, an elastic member 30, a second molded article 18, and a third molded article 20. The connection member 32 provides a valve function that can be opened by inserting a hollow needle 28 into a cavity having a slit (described below). Fig. 12B The elastic member 30 with the slit 31 shown in FIG. 3 is used to store and supply liquid.

[0047] FIG. 11A to FIG. 11C 3 is a schematic diagram showing a method for manufacturing the connection member 32. In this embodiment, the first molded article 17, the second molded article 18, and the third molded article 20 (see FIG. 2 ) are formed by injection molding using the injection molding apparatus 100. Fig.11A ). Thereafter, the elastic member 30 is provided to the first molded article 17 (see Fig. 11B ), and the second molded article 18 and the third molded article 20 are attached thereto and joined together (see Fig. 11C ). That is, in the first step, the first molded article 17, the second molded article 18, and the third molded article 20 are molded by primary molding, in the second step, the elastic member 30 is supplied to the first molded article 17 in the intermediate mold 6, and the second molded article 18 and the third molded article 20 are attached thereto. Next, the first molded article 17, the second molded article 18, and the third molded article 20 are joined together by secondary molding in the third step, and the completed connecting member 32 is removed from the intermediate mold 6 in the fourth step. The connecting member 32 can be manufactured through the above series of steps.

[0048] FIG. 12A to FIG. 12C 2 is a cross-sectional view showing the first molded article 17, the second molded article 18, and the third molded article 20 in the joining step. In the joining of the fourth step, the molten resin 23 is poured into the space formed by the molded articles to obtain an integral molded article. In the case where the molten resin 23 is poured into the space, while the elastic member 30 is compressed using the mold clamping force, the molded articles are appropriately pressed into contact with each other, so that the molded articles are stably held until the molten resin 23 is injected and cooled. This also eliminates the need for an additional compression device.

[0049] As described above, the intermediate mold in the injection molding machine includes a molded article removal mechanism. Therefore, it is possible to provide an article manufacturing method and manufacturing equipment capable of removing a molded article from the intermediate mold in the injection molding machine.

[0050] Although the present disclosure has been described with reference to exemplary embodiments, it is to be understood that the present disclosure is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

Claims

1. A method for manufacturing an article, comprising: A first molding step, which uses a first mold and an intermediate mold to perform molding; a rotating step of rotating the intermediate mold; an intermediate removing step of removing the molded article molded in the first molding step from the intermediate mold; as well as The second molding step is to perform molding using the second mold and the intermediate mold.

2. The article manufacturing method according to claim 1, wherein each of the first molding step and the second molding step comprises: performing mold closing by moving the second mold and the middle mold in a mold moving direction; as well as performing mold opening by moving the second mold and the intermediate mold in the mold moving direction, and Wherein, in the rotating step, the intermediate mold rotates around a rotation axis perpendicular to the moving direction of the mold.

3. The article manufacturing method according to claim 2, before the first forming step, further comprising: Arranging the first mold and the second mold, wherein the intermediate mold is located between the first mold and the second mold; as well as The second mold and the intermediate mold are supported by a supporting member, The supporting member extends in the direction in which the mold moves.

4. The article manufacturing method according to claim 3, wherein in the rotating step, the intermediate mold is rotated around an axis orthogonal to a surface supporting the intermediate mold. 5 . The article manufacturing method according to claim 1 , wherein in the rotating step, the intermediate mold is rotated 90 degrees relative to the first mold and the second mold.

6. The article manufacturing method according to claim 4, wherein in the intermediate removal step, the molded article is removed from the intermediate mold in an axial direction relative to the rotation axis by a lifting device.

7. The article manufacturing method according to claim 6, wherein the lifting device abuts against an ejector pin in the intermediate mold and is configured to lift and lower the ejector pin.

8. The article manufacturing method according to claim 7, further comprising a cam plate having an inclined portion, The cam plate is arranged in the middle mold and moves by the lifting and lowering of the ejector rod.

9. The article manufacturing method according to claim 8, further comprising an ejector pin configured to move in the mold moving direction in response to movement of an ejector plate along the inclined portion of the cam plate to eject the molded article.

10. The article manufacturing method according to claim 6, wherein in the intermediate removing step, the lifting device is configured to stop at different heights.

11. The article manufacturing method according to claim 1, wherein in the intermediate removing step, a plurality of molded articles are removed from the intermediate mold.

12. The article manufacturing method according to claim 7, wherein the lifting device is configured to be separated from the ejector pin.

13. The article manufacturing method according to claim 1, wherein the molding performed in the first molding step uses a first material, and the molding performed in the second molding step uses a second material different from the first material.

14. The method for manufacturing an article according to claim 1, further comprising: Final removal steps, wherein, after forming the molded article in the first molding step, removing the first molded article in the intermediate mold and attaching the first molded article to the second molded article in the intermediate mold in the intermediate removal step, wherein the second molding step further comprises welding the first molded article to the second molded article, and Wherein the final removing step comprises removing the welded first shaped article and the second shaped article from the intermediate mould.

15. A manufacturing device comprising: First mold; Second mold; an intermediate mold disposed between the first mold and the second mold, the intermediate mold comprising a first plurality of surfaces capable of being molded with the first mold and a second plurality of surfaces capable of being molded with the second mold, and A removal mechanism is configured to remove the formed article from the intermediate mold.

16. The manufacturing apparatus according to claim 15, wherein: The second mold and the intermediate mold are each configured to perform mold closing and mold opening with the first mold by moving in a mold moving direction, and The intermediate mold is configured to rotate about a rotation axis orthogonal to a direction of movement of the mold. 17 . The manufacturing apparatus according to claim 16 , wherein the second mold and the intermediate mold are supported by a supporting member extending in a moving direction of the molds.

18. The manufacturing apparatus of claim 15, wherein the intermediate mold is configured to rotate about an axis orthogonal to a surface supporting the intermediate mold.

19. The manufacturing apparatus of claim 15, wherein the intermediate mold is configured to be rotated 90 degrees relative to the first mold and the second mold.

20. The manufacturing apparatus according to claim 18, wherein the molded article is removed from the intermediate mold in an axial direction relative to the rotation axis by a lifting device.

Images