Method for producing mould components and method for controlling a production device

Abstract

A method for manufacturing a mold member is disclosed, comprising: molding a first article and a second article, the first article remaining in a first mold; molding a third article, the third article remaining in the second mold; assembling the second article to the first article; moving at least one of the first mold and the second mold to assemble the second article onto the third article, wherein the first article remaining in the first mold is opposed to the third article remaining in the second mold; forming a joined shape portion by combining the first article assembled with the second article with the third article; and combining the first mold and the second mold and joining the first mold and the second mold by pouring a joining resin into the joining shape portion.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a mold member and a method for controlling a manufacturing apparatus. Background Art

[0002] In recent years, a system using molten resin has been adopted in order to improve the joint reliability and joint strength and reduce the equipment cost when joining together molded products supplied by a molding method represented by injection molding. Specifically, an injection molding machine is used to mold a plurality of single parts. Then, once the mold is opened to move so that the single parts are opposite to each other, the mold is closed again in this state, and the molded single parts are combined together to form a space for joining. Molten resin is poured into the space and joined. By adopting this system, each step up to the joining step can be completed using a single injection molding machine. The molded products formed on the mold can be placed in positions relative to each other by moving the mold. Therefore, it is expected to improve the positional accuracy of the parts, such as relative position and parallelism. In addition, the clamping force of the injection molding machine can be used for pressure contact of the parts.

[0003] However, in such a system, the step of forming a molded product and the step of pouring a molten resin cannot be performed simultaneously. A method in which a rotatable intermediate mold is provided to form a molded product with one of a plurality of molds and a first surface of the intermediate mold. With the molded product remaining in the intermediate mold, the intermediate mold is rotated 180 degrees so as to move the molded product to the second surface of the intermediate mold. Another mold is used for pouring the molten resin, and the second surface of the intermediate mold can be used. Therefore, the corresponding steps can be performed in parallel on both surfaces, improving productivity. In this case, it can be considered that by rotating the intermediate mold 90 degrees each time to use a supply device on the operating side and the reverse operating side of the molding machine to assemble a component on the mold, insert another component, or discharge a product.

[0004] Japanese Patent Laid-Open No. 2018-27686 (hereinafter referred to as Reference 1) discusses a technology related to a molded product formed by joining a first component, a second component, and a third component with a joining resin. Japanese Patent Laid-Open No. 2016-215561 (hereinafter referred to as Reference 2) discusses a technology for relatively moving the position of a mold by a die slide.

[0005] In reference 1, a mold is used to manufacture a molded product by the following steps: a primary molding step of molding a first component, a second component, and a third component; an assembling step of assembling the three components in the mold; and a secondary molding step of filling a joining shape portion formed between the assembled three components with a joining resin. In the technology of reference 1, two assembling operations are required to combine the three components.

[0006] Reference 2 discusses that in the case where the position of the mold is relatively moved by a mold slide, each component can be easily assembled, but in the case where the number of components is large, as many sliding mechanisms as the components are required and the mold becomes a complicated large mold.

[0007] In the case where there is an inserted member, assembly using a slider cannot be performed. In this case, it is desirable to remove the molded product from the mold using a robot or the like, and then perform assembly. In this case, a gap is required between one component to be assembled to another component and the other component. Therefore, a play is generated between the assembled components. This play occurs between the combined components, and as the number of assembly operations increases, the play becomes larger overall.

[0008] The three components stacked in the assembly step in Reference 1 are clamped again in the secondary molding step, accommodated in the space for secondary molding, and joined together with a bonding resin. However, there is a possibility that the bonding shape portion formed between the assembled components is not formed correctly due to the clearance in the assembled components and the bonding resin leaks out. In addition, there is a possibility that the three components are not accommodated in the space in the case of the clamping operation of the secondary molding step and the molded product is scratched or clamped between the molds. In the case of performing assembly many times, the time taken for the assembly step increases and the tact time increases. Summary of the invention

[0009] One aspect of the present disclosure provides a manufacturing method, which uses a mold having a first mold and a second mold relative to each other to mold at least three molded products and join the molded products with a joining resin, the method comprising: molding a first product and a second product, wherein the first product remains in the first mold; molding a third product, wherein the third product remains in the second mold; assembling the second product onto the first product; moving at least one of the first mold and the second mold to assemble the second product onto the third product, wherein the first product remaining in the first mold and assembled with the second product is opposite to the third product remaining in the second mold; forming a joining shape portion by combining the first product assembled with the second product with the third product; and combining the first mold with the second mold and combining by pouring the joining resin into the joining shape portion.

[0010] 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

[0011] Figure 1 is a diagram showing a joining component;

[0012] Figure 2 is a diagram showing a state immediately before three components are joined together with a joining resin;

[0013] Figure 3 is a schematic diagram of the mold;

[0014] Figure 4A and Figure 4B is a diagram showing manufacturing steps;

[0015] Figure 5 is a diagram showing manufacturing steps;

[0016] Figure 6 is a diagram showing manufacturing steps;

[0017] Figure 7 is a diagram showing the assembly of three components;

[0018] Figure 8 is a schematic diagram of a liquid ejection device;

[0019] 9A to 9C is a diagram showing a connection portion of a liquid holding container;

[0020] FIG. 10A to FIG. 10C is a diagram showing a joint portion of a connection portion for a liquid holding container;

[0021] Fig.11A and Fig. 11Bis a diagram showing manufacturing steps;

[0022] Fig.12 is a diagram showing manufacturing steps; and

[0023] Fig.13 It is a figure which shows the manufacturing steps. DETAILED DESCRIPTION

[0024] The preferred embodiments of the present disclosure are specifically explained below with reference to the accompanying drawings. Incidentally, the following embodiments do not limit the present disclosure, and not all combinations of the features explained in the following embodiments are essential to the present disclosure. The same components are indicated by the corresponding same reference numerals. In addition, the relative positions, shapes, etc. of the components described in the embodiments are only examples, and the scope of the present disclosure is not intended to be limited to these.

[0025] Figure 1 is a diagram showing a joining component according to the present embodiment. The joining component has a configuration in which a first molded product 1, a second molded product 2, and a third molded product 3 are joined together with a joining resin 4. In the case of joining, different types of members (insertion members), for example, a rubber member or a filter, may be inserted between the molded products. Figure 1 An example is shown in which the elastic member 5 is inserted as the insertion member.

[0026] Figure 2 1 is a diagram showing a state immediately before three components (including a first molded product 1 , a second molded product 2 , and a third molded product 3 ) are joined together with a joining resin. Figure 2 Various aspects of the embodiments of the present invention are not shown, but are provided as examples for comparison. Figure 2 In the mold 6, the first molded product 1 remains in the mold 6. In the mold 6, another component is assembled to the first molded product 1. As mentioned earlier, a gap is required for assembly. Therefore, the components may deviate or tilt due to the gap. As the number of components to be assembled increases, gaps appear between the components and the overall deviation becomes larger. In this state, the components have a configuration in which they are accommodated in a space (in which the components are to be joined with the joining resin 4) by being clamped. However, in the case where the deviation is too large, the molded product may not be accommodated in the space and clamped by the mold 6. In addition, in Figure 2In the configuration of , engagement is performed while the inserted elastic member 5 is compressed by clamping. In this case, when the second molded product 2 is assembled, the second molded product 2 is forced (i.e., floats) away from the first molded product 1 due to the reaction force of the rubber. Therefore, the assembly portion of the second molded product 2 cannot extend too deep into the first molded product (to which the second molded product is to be assembled by clamping). A guide formed by a taper is usually provided to the assembly portion for easy assembly. Therefore, since the assembly portion cannot extend too deep into the first molded product, the gap increases and the deviation and inclination also increase.

[0027] Figure 3 is a schematic diagram of a three-plate mold according to the present embodiment, the three-plate mold having a first mold 11 attached to a first platen 9 of a molding machine, a second mold 12 attached to a second platen 10 of the molding machine, and an intermediate mold 13 located between the first mold 11 and the second mold 12, wherein the intermediate mold 13 rotates. Figure 3 , the X direction is the mold opening-closing direction. The intermediate mold 13 rotates 360 degrees around an axis extending in the Z direction orthogonal to the mold opening-closing direction. The LM (Linear Motion) guide 14 attaching the intermediate mold 13 to the second platen 10 of the molding machine simplifies positioning when clamping. A primary molded product can be molded between the first mold 11 and the intermediate mold 13 and between the second mold 12 and the intermediate mold 13. Secondary molding is performed by joining the primary molded product together with a joining resin between the second mold 12 and the intermediate mold 13. Secondary molding is performed by rotating the intermediate mold 13.

[0028] An example of a method for manufacturing a mold member using a manufacturing apparatus including such a mold is explained below.The mold member refers to a member manufactured by using a mold.

[0029] Figure 4A and Figure 4B , Figure 5 and Figure 6 2 is a diagram showing the manufacturing steps in this embodiment. FIG. 4A to FIG. 6 It is observed from above Figure 3 As a first step of molding a molded product, a primary molding is performed. In the first step, as Figure 4A As shown, the first molded product 1 and the second molded product 2 are molded in the space (ie, the cavity) formed between the first mold 11 and the middle mold 13 by the first injection unit 7. Figure 4A As shown, the third molded product 3 is molded in a portion (ie, a part) of the space formed between the second mold 12 and the intermediate mold 13, and secondary molding is performed in the space by using the molding resin 4. After molding, as shown in FIG. Figure 4BAs shown, the second mold 12 and the intermediate mold 13 move in the -X direction, thereby separating each of the molds. Figure 3 As shown, the second platen 10 of the molding machine provided with the second mold 12 and the intermediate mold 13 are movable molds. Therefore, the second mold 12 and the intermediate mold 13 are configured to be movable together in the mold opening-closing direction (X direction). Figure 4B As shown, the first molded product 1 and the second molded product 2 remain on one side of the middle mold (middle mold 13 ), and the third molded product 3 remains on one side of the second mold (second mold 12 ).

[0030] Then, the second step of assembling the molded product according to this embodiment is carried out. In the second step, as Figure 5 As shown, the middle mold is rotated 90 degrees. The robot 15 (for example, a six-axis robot) is set at a position opposite to the position where the first molded product 1 and the second molded product 2 are rotated 90 degrees. Figure 5 As shown, the robot 15 assembles the second molded product 2 onto the first molded product 1, which remains in the intermediate mold 13, as formed in the first step. In this case, the insertion of the elastic member 5 and the different member types (e.g., filters) is also performed. As described herein, the third molded product 3 is molded in the space where the secondary molding is performed. Therefore, the number of times the components are assembled is reduced by one compared to the case where all three components are molded between the first mold 11 and the intermediate mold 13. Therefore, the potential deviation of the assembled components is reduced in the second step.

[0031] As the third step of this embodiment, the three parts are joined by performing secondary molding. Figure 6 As shown, the middle mold is Figure 5 The rotation movement makes the space of the third molded product 3 molded in the first step aligned with the first molded product 1 assembled with the second molded product 2, that is, opposite. Figure 6 As shown, the second mold 12 (the second platen 10 of the molding machine) moves in the mold closing direction (+X direction) to perform another clamping operation. The three components are assembled in this space by the clamping operation, and the three components are joined together by pouring the joining resin 4 (which is a molten resin) into the joining shape portions formed in the three components.

[0032] Figure 71 is a diagram showing the assembly of the three parts in a space for secondary molding. One side of the second molded product 2 is not held by the mold. The first molded product 1, the second molded product 2, and the third molded product 3 have an assembly part assembled in the assembled state. When the clamping operation causes the assembly part to correct the misalignment and tilt of the second molded product 2, the second molded product 2, the first molded product 1, and the third molded product 3 are positioned and joined.

[0033] After molding in the first step, the third molded product 3 is held in the space for secondary molding without being removed from the mold (second mold 12) before the third step. Figure 7 As shown, there is no inclination or misalignment in the third molded product 3 , so that the third molded product 3 can be assembled to the first molded product 1 and the second molded product 2 .

[0034] By the way, in Figure 6 In the example shown, the second mold 12 (i.e., the second platen 10 of the molding machine) moves in the +X direction, and the intermediate mold 13 also moves in the +X direction, and clamping is performed. The intermediate mold 13 is installed in the second platen 10 of the molding machine, and the second mold 12 and the intermediate mold 13 are movable and are subjected to a clamping force by being pressed against one side of the first mold 11 (the first platen 9 of the molding machine). Therefore, the second mold 12 and the intermediate mold 13 move in the +X direction. However, the configuration is not limited to this example. A configuration in which the first mold 11 and the second mold 12 are movable relative to the intermediate mold 13 may also be applicable. In this case, as long as Figure 6 The embodiment in which only the second mold 12 is moved in the illustrated assembly steps is an embodiment in which the first mold 11 and the second mold 12 are independently movable, and this embodiment is applicable.

[0035] Figure 8 is a schematic diagram of the liquid ejecting device 16 . 9A to 9C The connecting portion 21 of the liquid holding container 18 is shown. Fig. 10A and Fig. 10B 1 is a diagram showing a joining member for the connection portion 21 of the liquid storage container 18. Figures 8 to 10B A specific example of using the injection molding machine (manufacturing apparatus) of the present embodiment in the liquid containing container 18 of the liquid ejecting apparatus 16 will be explained. Incidentally, the liquid ejecting apparatus 16 of the present embodiment is an inkjet printer.

[0036] like Figure 8 As shown, the liquid ejection device 16 has a liquid ejection head 17, a liquid storage container 18, a tube 19 and a hollow needle 20. Incidentally, Figure 8The examples shown are diagrammatic illustrations for showing an overview, and configurations other than these features may be included. The liquid ejection head 17 may be a line type liquid ejection head that continuously performs printing in one stroke while continuously and intermittently conveying a plurality of print media, or a serial liquid ejection head that performs printing by repeating conveyance of print media and reciprocating scanning of the liquid ejection head 17. The liquid ejection device 16 may include a liquid holding container 18 of a K (black) monochrome color, or in order to be able to perform full-color printing of CMYK (cyan, magenta, yellow, and black) inks, may include liquid holding containers 18 corresponding to the respective colors.

[0037] The liquid storage container 18 that stores liquid communicates with the liquid ejecting head 17 via the tube 19 and the hollow needle 20. The liquid stored in the liquid storage container 18 is supplied to the liquid ejecting head 17 through the hollow needle 20 and the tube 19.

[0038] In manufacturing Figure 8 In the case of the connecting portion 21 of the liquid containing container 18 shown or the like, the connecting portion 21 is molded as a connecting member formed of a connecting resin. Fig.9A It is a perspective view of the liquid storage container 18. Fig. 9B It is an exploded perspective view in which a part of the connecting portion 21 in the liquid holding container 18 is disassembled. Fig. 9C 2 is a cross-sectional view of a state in which the hollow needle 20 is inserted into the connecting portion 21 (ie, a state in which the liquid ejecting device 16 is equipped with the liquid containing container 18). 9A to 9C As shown, the connecting portion 21 has a configuration in which a hollow needle 20 is inserted into the elastic member 5 having a notch. This configuration provides a valve function, which enables the connecting portion 21 to hold and supply liquid. Fig. 9B and Fig. 9C As shown, the connection portion 21 is a joining part including the first molded product 1 , the second molded product 2 , the third molded product 3 , and the elastic member 5 .

[0039] FIG. 10A to FIG. 10C 2 is a diagram showing a joining member as a connecting portion 21. Fig. 10A As shown, a first molded product 1, a second molded product 2, and a third molded product 3 are formed by injection molding. Next, as Fig. 10B As shown, the elastic member 5 is supplied to the first molded product 1. In addition, as Fig. 10C As shown, the second molded product 2 and the third molded product are assembled to the first molded product 1 supplied with the elastic member 5 and joined together. Figure 1As in the joining parts shown in , by pouring the joining resin 4 into the space formed by the molded product, the joining can provide an integral molded product. In the injection molding machine apparatus of this embodiment, in addition to molding the first molded product 1 and the second molded product 2, a part of the space in which the secondary molding is performed is also used to mold the third molded product 3.

[0040] As explained herein, the present embodiment can suppress the occurrence of play in the entire combination of components and reduce the cycle time of the assembly step. Specifically, in a joined component obtained by joining molded products corresponding to at least three components and requiring two or more assembly operations in the assembly step, multiple components can be assembled into one in a secondary molding step while reducing the number of assemblies in the assembly step. The reduction in the number of times the assembly is performed makes the assembly itself easy and reduces the play between the combinations of components. In addition, the primary molded product molded in the secondary molding space is joined without being removed from the mold. That is, the primary molded product molded in the secondary molding space is positioned by the mold and does not generate play. In addition, the reduction in the number of assembly operations can shorten the cycle time in the assembly step.

[0041] Furthermore, in the above example, the steps of manufacturing one component are explained, but a plurality of components may be manufactured continuously. Figure 6 In the state, the first mold 11 and the intermediate mold 13 can be used to mold the same Figure 4A to continuously manufacture the joined parts.

[0042] In addition, as explained in the present embodiment, the corresponding steps can be distributed to other surfaces by using the rotating intermediate mold 13, and thus the space efficiency can be improved. In addition, operations can be performed in parallel on the corresponding surfaces, and thus the productivity can be improved.

[0043] In the first embodiment, an example of performing the primary molding step, the assembly step, and the secondary molding step using the first mold 11, the second mold 12, and the intermediate mold 13 is explained. In the second embodiment, an example of performing the primary molding step, the assembly step, and the secondary step without using the intermediate mold is explained. In the second embodiment, either the first platen 9 of the molding machine on which the first mold 11 is mounted or the second platen 10 of the molding machine on which the second mold 12 is mounted is a movable platen.

[0044] Fig.11A and Fig. 11B , Fig.12 and Fig.13 are diagrams showing manufacturing steps in the second embodiment. Fig.11A and Fig. 11B , Fig.12 and Fig.13 They are respectively Figure 4A and Figure 4B , Figure 5 and Figure 6 Schematic illustration of the corresponding situation. In the second embodiment, the second mold 12 has a sliding mechanism 121 that can slide.

[0045] As a first step, a step of molding a molded product (i.e., primary molding) is performed. In the first step, as Fig.11A As shown, the first molded product 1 and the second molded product 2 are molded in the space formed in the first mold 11 by the first injection unit 7. In this case, as shown in FIG. Fig.11A As shown, a part of the space formed in the second mold 12 is also used to mold the third molded product 3, and in this space, secondary molding will be performed with the bonding resin 4. After molding, as shown in FIG. Fig. 11B As shown, since the second mold 12 moves in the -X direction, each mold is separated. Fig. 11B As shown, the first molded product 1 and the second molded product 2 remain in the first mold 11 , and the third molded product 3 remains in the second mold 12 .

[0046] As a second step, the molded product is assembled. In the second step, as Fig.12 As shown, the robot 15 intrudes into the opening between the molds and then assembles. As explained in the first embodiment, in this case, the insert member, such as the elastic member 5, is also assembled. In addition, as Fig.12 As shown, the third molded product 3 moves to a position opposite to the first molded product 1 and the second molded product 2 due to the movement of the sliding mechanism 121 .

[0047] As mentioned previously, the third molded product 3 is molded using the space for secondary molding in the first step. Therefore, the number of times the components are assembled is reduced by one compared to the case where all three components are molded in the first mold 11. Therefore, the total deviation amount of the assembled components occurring in the second step can be reduced.

[0048] As a third step, the three parts are joined together, i.e., secondary molding is performed. Fig.13 As shown, since the second mold 12 is Fig.12 This clamping operation assembles the three components in space, and joins the three components together by pouring a joining resin 4 into a joining shape portion formed in the three components.

[0049] As explained above, the second embodiment which does not use the intermediate mold can suppress the play generated between the combinations of the components and reduce the tact time of the assembly step.

[0050] In the discussion of the first and second embodiments, the first mold 11 does not move. However, the first and second embodiments are not limited thereto, and the movement of the first mold 11 may be applicable. In another embodiment, the first mold 11 moves, while the second mold 12 and the intermediate mold 13 do not move. In other words, in the first embodiment, at least one of the first mold 11, the second mold 12, and the intermediate mold 13 needs to be configured to be movable. In the second embodiment, only at least one of the first mold 11 and the second mold 12 is required to be movable.

[0051] In addition, in the first embodiment and the second embodiment, the method of manufacturing a mold member using a manufacturing device for manufacturing a mold member is explained. The example explained in the first embodiment and the second embodiment is also a method for controlling a manufacturing device for manufacturing a mold member. The aforementioned steps are performed by controlling a control unit or the like.

[0052] 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 manufacturing method for molding at least three molded products using a mold having a first mold and a second mold facing each other and bonding the molded products with a bonding resin, the method comprising: molding a first article and a second article, wherein the first article remains in the first mold; molding a third article, wherein the third article remains in the second mold; assembling the second product onto the first product; moving at least one of the first mold and the second mold to assemble the second product onto the third product, wherein the first product remaining in the first mold and assembled with the second product is opposite to the third product remaining in the second mold; forming a joined shape portion by combining the first product assembled with the second product and the third product; as well as The first mold and the second mold are combined and joined by pouring the joining resin into the joining shape portion. 2 . The method of claim 1 , wherein in the assembling, the second article is removed from the mold to be assembled onto the first article.

3. The method according to claim 1, wherein in the joining, the second product, the first product, and the third product are positioned and joined together while correcting misalignment and tilt of the second product by a clamping operation.

4. The method according to any one of claims 1 to 3, wherein in the joining, one side of the second article is not held by the mold.

5. The method according to any one of claims 1 to 3, wherein the assembling comprises inserting an insert member into a primary article.

6. The method according to any one of claims 1 to 3, wherein the bonding resin is a molten resin.

7. A manufacturing method for molding at least three molded products using a mold having opposing first and second molds and an intermediate mold disposed between the first and second molds and bonding the molded products together with a bonding resin, the method comprising: molding a first article and a second article between the first mold and the intermediate mold, wherein the first article and the second article remain in the intermediate mold; molding a third article between the second mold and the intermediate mold, wherein the third article remains in the second mold; assembling the second molded article onto the first article; moving at least one of the intermediate mold and the second mold to assemble the second product onto the third product, wherein the first product remaining in the intermediate mold and assembled with the second product is opposite to the third product remaining in the second mold; forming a joined shape portion by combining the first product assembled with the second product and the third product; as well as The intermediate mold is combined with the second mold and bonding is performed by pouring the bonding resin into the bonding shape portion.

8. The method according to claim 7, wherein the intermediate mold rotates around an axis orthogonal to the mold opening-closing direction. 9 . The method according to claim 8 , wherein the intermediate mold moves together with the second mold in the mold opening-closing direction.

10. The method of claim 7, wherein in said assembling, said second article is removed from said mold for assembly onto said first article.

11. The method according to claim 7, wherein in the joining, the second product, the first product, and the third product are positioned and joined together while correcting misalignment and tilt of the second product by a clamping operation.

12. The method of any one of claims 7 to 11, wherein a side of the second article is not held by one or more of the first mold, the second mold, or the intermediate mold during the joining.

13. A method according to any one of claims 7 to 11, wherein said assembling comprises inserting an insert member into a primary article.

14. The method according to any one of claims 7 to 11, wherein the bonding resin is a molten resin.

15. A manufacturing method using a three-plate mold, the method comprising: molding a first article and a second article in a first mold of the three-plate mold; molding a third article in the second mold of the three-plate mold; moving at least one of the first mold and the second mold; assembling the second product onto the first product; moving at least one of the first mold and the second mold to align the third article with the assembled first and second articles; as well as The second article is assembled to the third article, wherein the assembled first and second articles are held in the first mold and the third article is held in the second mold. 16 . The method according to claim 15 , wherein the molding of the first article and the second article is performed simultaneously with the molding of the third article.

17. The method of claim 15, wherein the assembled first and second articles are combined with the third article by bonding.

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