Molded product manufacturing method and manufacturing apparatus

Abstract

The invention relates to a molded article manufacturing method and a manufacturing apparatus. The molded article manufacturing method includes the steps of: molding a first component and a second component between a first surface and an A surface; molding a third component and a fourth component between the first surface and the B surface and engaging the second component with the first component held on the A surface; welding the first part and the second part to mold a first integral molded article, and joining the fourth part with the third part held on the B surface; and welding the third component and the fourth component to mold a second unitary molded article.

Description

Technical Field

[0001] The present disclosure relates to a method and an apparatus for manufacturing molded articles. Background Art

[0002] The specification of European Patent No. 1628819 discloses a manufacturing apparatus that includes an intermediate mold located between a first mold and a second mold. The manufacturing apparatus of the specification of European Patent No. 1628819 performs molding using the first mold and the intermediate mold in a first step, rotates the intermediate mold by 90° while leaving the molded article on the intermediate mold, then assembles a plurality of molded articles on the intermediate mold in a second step, and thereafter rotates the intermediate mold by 90°. In a third step, the manufacturing apparatus connects the plurality of molded articles thus assembled to the second mold and the intermediate mold by using molten resin, and then rotates the intermediate mold by 90°. Finally, in a fourth step, the manufacturing apparatus discharges the plurality of molded articles thus connected from the intermediate mold. Then, the manufacturing apparatus sequentially performs the above-described first step to fourth step continuously and orderly on four surfaces of the intermediate mold while switching these steps one by one. Since the manufacturing apparatus can perform each step simultaneously and in parallel in this way, productivity is improved.

[0003] However, the manufacturing apparatus of the specification of European Patent No. 1628819 is used to manufacture a plurality of products of one type, and does not describe molding of two or more types of products. In addition, although the manufacturing apparatus of the specification of European Patent No. 1628819 can combine two molded parts, it cannot handle more complex molding, for example, it cannot perform molding that combines three parts. Summary of the Invention

[0004] Therefore, the present disclosure provides a method and an apparatus for manufacturing molded articles that can perform complex molding.

[0005] To this end, the molding method of the present disclosure is a molding method of a molded article, which uses: a first mold having a first surface; a second mold having a second surface; and an intermediate mold having surfaces A, B, C, and D, each surface being capable of facing the first surface and the second surface, and the intermediate mold being capable of changing the surface facing the first surface and the second surface by rotating between the first mold and the second mold. The molding method of the molded article includes: a first molding step: by closing the first mold and the intermediate mold in a state where the surface A faces the first surface and injecting molten resin into the mold, molding a first component and a second component between the first surface and the surface A; a second molding step: by closing the first mold and the intermediate mold in a state where the surface B faces the first surface and injecting molten resin into the mold, molding a third component and a fourth component between the first surface and the surface B, and causing the second component to be joined to the first component held on the surface A; a third molding step: by closing the second mold and the intermediate mold in a state where the surface A faces the second surface and injecting molten resin into the mold, welding the first component and the second component to mold a first integral molded article, and causing the fourth component to be joined to the third component held on the surface B; and a fourth molding step: by closing the second mold and the intermediate mold in a state where the surface B faces the second surface and injecting molten resin into the mold, welding the third component and the fourth component to mold a second integral molded article, which is different from the first integral molded article.

[0006] According to the present disclosure, a molding method and a manufacturing apparatus for a molded article capable of performing complex molding can be provided.

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

[0008] Figure 1 is a schematic view showing a manufacturing apparatus including a rotatable intermediate mold;

[0009] Figure 2 is a schematic view showing a molded product that can be molded by this manufacturing apparatus;

[0010] Figure 3 is a schematic view showing an image of a molded article in which a plurality of components are assembled in a conventional manufacturing apparatus;

[0011] Figure 4A is a schematic view showing a manufacturing apparatus;

[0012] Figure 4B 、 Figure 4C 、 Figure 4D and Figure 4E is a schematic diagram showing an area on the surface of an intermediate mold;

[0013] Figure 5A is a side view showing a manufacturing apparatus;

[0014] Figure 5B 、 Figure 5C and Figure 5D is a simplified diagram showing the mold surface;

[0015] Figure 6A 、 Figure 6B 、 Figure 6C and Figure 6D is a simplified diagram illustrating a molding process;

[0016] Figure 7 is a simplified diagram showing a molded product;

[0017] Figure 8A 、 Figure 8B 、 Figure 8C 、 Figure 8D and Figure 8E is a schematic diagram showing the first step;

[0018] Figure 9A 、 Figure 9B 、 Figure 9C 、 Figure 9D and Figure 9E is a schematic diagram illustrating the second step; and

[0019] Figure 10A 、 Figure 10B 、 Figure 10C and Figure 10D is a simplified diagram showing a molding process in a modification. DETAILED DESCRIPTION

[0020] (First embodiment)

[0021] Hereinafter, a first embodiment of the present disclosure will be described with reference to the accompanying drawings.

[0022] Figure 1FIG. 0 is a schematic view showing a manufacturing apparatus 100 including a rotatable intermediate mold in the present disclosure. The manufacturing apparatus 100 includes a first mold 03, a second mold 04, and an intermediate mold 05, and the intermediate mold 05 is disposed between the first mold 03 and the second mold 04. The intermediate mold 05 includes four surfaces, all of which can face the first mold 03 and the second mold 04, and the intermediate mold can change the surface facing the first mold 03 or the second mold 04 by rotating 90° each time. Both the first mold 03 and the second mold 04 can perform molding by closing with the intermediate mold 05.

[0023] The first mold 03 is fixed to a fixed template 01, and the fixed template 01 is fixed to an end portion of a linear slider 90. The second mold 04 is fixed to a movable template 02, and the movable template 02 is supported on the linear slider 90 so as to be movable on the linear slider 90. An injection unit 06 is disposed in the fixed template 01, and the injection unit 06 injects molten resin into the first mold 03. An injection unit 07 is disposed on the movable template 02, and the injection unit 07 injects molten resin into the second mold 04.

[0024] Figure 2 FIG. 7 is a schematic view showing a molded product 200 that can be molded by the manufacturing apparatus 100. The molded product 200 includes a first molded article 08, an elastic member 14, a second molded article 09, and a third molded article 12. The first molded article 08, the second molded article 09, and the third molded article 12 are connected (welded). Note that in the manufacturing process continuously performed in the manufacturing apparatus 100, two molded products having different shapes are manufactured; however, each molded product is molded using three molded articles and one elastic member. Therefore, in Figure 2 For simplicity of description, it is assumed that the two molded products have the same shape, and a single member is marked with multiple labels, such as the first molded article 08, 10, the second molded article 09, 11, the third molded article 12, 13. In Figure 2 One of these labels (the first molded article 08, the second molded article 09, and the third molded article 12) is used for description.

[0025] In the manufacturing process of the molded product 200, the elastic member 14 is inserted into the first molded article 08, and the second molded article 09 is mounted on the first molded article 08. Thereafter, the third molded article 12 is mounted, and molten resin 15 is poured into the space portion thus formed by the injection unit 07 to connect the components. In this way, the molded product 200 is molded. As the molten resin 15, a material different from the materials of the first molded article 08, the second molded article 09, and the third molded article 12 may be used, or the same material may be used.

[0026] Figure 3It is a schematic diagram showing how to assemble three components in a mold. Figure 3 It shows the state where other components are mounted on the first molded product 08 molded in the mold. Here, it shows the case where the elastic member 14, the second molded product 09, and the third molded product 12, which are other components, are mounted on the first molded product 08. The first molded product has been molded between the first mold 03 and the intermediate mold 05 and is held on the intermediate mold 05. The second molded product 09 and the third molded product 12 are components molded in a molding step, which is a step before installation. Figure 3 It shows the case where the second molded product 09 and the third molded product 12 are taken out of the mold after molding and mounted on the first molded product 08.

[0027] Contact and assembly require a gap, which is for accommodating the unevenness of the mating components, and this gap includes an error area for ensuring engagement. For this reason, the larger the number of components, the greater the cumulative error, making it more likely that the components will shift or tilt due to the gap during assembly. In particular, tilting sometimes occurs in the case of taking out the components from the mold after molding and assembling the components as shown Figure 3 However, in the case where the shift or tilt is excessive, there will be a situation where the molded product is not assembled into the space part of the mold and is squeezed by the mold, resulting in molding failure. Therefore, in this embodiment, it is configured such that the second molded product 09 is taken out of the mold and mounted on the first molded product 08, but the third molded product 12 is mounted on the first molded product 08 while being held on the second mold 04.

[0028] Figure 4A It is a top view showing the manufacturing apparatus 100 of this embodiment. Figures 4B to 4E It is a schematic diagram showing the areas of two molded products corresponding to the respective surfaces of the intermediate mold 05. As shown Figure 4A The intermediate mold 05 includes four surfaces (surface A 41 to surface D 44) and rotates 90 degrees each time. By this rotation of the intermediate mold 05, the first mold 03 and the second mold 04 are sequentially faced with the surface A 41 of the intermediate mold 05 (see Figure 4B ), surface B 42 (see Figure 4C ), surface C 43 (see Figure 4D ), and surface D 44 (see Figure 4E ).

[0029] The A surface 41 to the D surface 44 of the intermediate mold 05 include areas for molding two molded products. The A surface 41 includes a first A surface area 41a and a second A surface area 41b, the B surface 42 includes a first B surface area 42a and a second B surface area 42b, the C surface 43 includes a first C surface area 43a and a second C surface area 43b, and the D surface 44 includes a first D surface area 44a and a second D surface area 44b. Moreover, the first A surface area 41a includes an upper area 21, and the second A surface area 41b includes an upper area 16 and a lower area 17. The first B surface area 42a includes an upper area 19 and a lower area 18, and the second B surface area 42b includes a lower area 20. The first C surface area 43a includes an upper area 21', and the second C surface area 43b includes an upper area 16' and a lower area 17'. The first D surface area 44a includes an upper area 19' and a lower area 18', and the second D surface area 44b includes a lower area 20'.

[0030] Since the intermediate mold 05 alternately molds each type of part every 90 degrees, the A surface 41 and the C surface 43 include the same areas, and the B surface 42 and the D surface 44 include the same areas. Additionally, in each area of the A surface 41 to the D surface 44, a module for molding a molded product is provided. The module is made to be capable of molding not only one molded product but also multiple identical molded products, such that a large number of modules can be processed to efficiently produce products.

[0031] Figure 5A is a side view showing the manufacturing apparatus 100. Figure 5B shows the first surface 50 of the first mold 03, Figure 5C shows the second surface 51 of the second mold 04 in the case where the module is provided in the lower part, and Figure 5D shows the second surface 51 of the second mold 04 in the case where the module is provided in the upper part.

[0032] The first surface 50 includes a first area 50a and a second area 50b, and the first area 50a includes an upper area 22 and a lower area 23. The second area 50b includes an upper area 25 and a lower area 24. The second surface 51 includes a first area 51a and a second area 51b, and includes: an area 26 that moves in the vertical direction in the first area 51a; an area 27 that moves in the vertical direction in the second area 51b. The area 26 and the area 27 move in an adjacent state to each other.

[0033] The upper region 22 of the first region 50a in the first surface 50 corresponds to the upper region 16 of the second region 41b of the A surface 41 in the intermediate mold 05 or the upper region 16' of the second region 43b of the C surface, and molds the first molded article 08. The lower region 23 of the first region 50a corresponds to the lower region 17 of the second region 41b of the A surface 41 in the intermediate mold 05 or the lower region 17' of the second region 43b of the C surface, and molds the second molded article 09.

[0034] The upper region 25 of the second region 51b in the first surface 50 corresponds to the upper region 19 of the first region 42a of the B surface 42 in the intermediate mold 05 or the upper region 19' of the first region 44a of the D surface, and molds the first molded article 10. The lower region 24 of the second region 51b corresponds to the lower region 18 of the first region 42a of the B surface 42 in the intermediate mold 05 or the lower region 18' of the first region 44a of the D surface, and molds the second molded article 11.

[0035] The region 26 that moves in the first region 51a of the second surface 51 corresponds to the lower region 20 in the second region 42b of the B surface of the intermediate mold 05 or the lower region (partial region) 20' of the second region 44b of the D surface, and molds the third molded article 12.

[0036] The region 27 that moves in the second region 51b of the second surface 51 corresponds to the upper region 21 in the first region 41a of the A surface of the intermediate mold 05 or the upper region 21' of the first region 43a of the C surface, and molds the third molded article 13.

[0037] Figures 6A to 6D is a schematic diagram showing the molding process in this embodiment. In this embodiment, two types of integral molded articles are molded alternately and repeatedly. Hereinafter, the molding process in this embodiment will be described in the order of steps. Note that since the molding process is continuously and simultaneously implemented, the process on the A surface 41 of the intermediate mold 05 will be described here, while referring to other surfaces (B surface 42, C surface 43, and D surface 44).

[0038] At Figure 6AIn the first step shown, with the first mold 03 and the intermediate mold 05 already closed, molten resin is injected into the mold from the injection unit 06. In this way, a first molded article 08 is molded between the upper region 22 of the first region 50a in the first surface 50 of the first mold 03 and the upper region 16 of the A surface 41 of the intermediate mold 05. Also, a second molded article 09 is molded between the lower region 23 of the first region 50a and the lower region 17 of the second region 41b of the A surface 41 of the intermediate mold 05. When the mold is opened after molding, the first molded article 08 and the second molded article 09 remain on the intermediate mold 05.

[0039] Here, the method for leaving the molded article on the intermediate mold 05 is to provide a draft angle on the outer periphery of the molded article so that the molded article is removed from the first mold 03 and remains on the intermediate mold 05 when the mold is opened. Note that depending on the shape of the molded article or the configuration of the mold, the molded article can also be left on the mold where it is desired to leave the molded article by using an ejector pin to project the molded article on the opposite side of the side where it is desired to leave the molded article when the mold is opened.

[0040] In Figure 6B In the second step shown, after the intermediate mold 05 is rotated 90 degrees in the direction of arrow α, the elastic member 14 is inserted into the first molded article 08 molded on the upper region 16 of the A surface 41 of the intermediate mold 05 by using the first assembly robot 29. After inserting the elastic member 14, the second molded article 09 molded on the lower region 17 of the A surface 41 is removed from the intermediate mold 05 by using the first assembly robot 29 and moved to abut and mount on the first molded article 08.

[0041] In addition, with the first mold 03 and the intermediate mold 05 already closed, molten resin is injected into the mold from the injection unit 06. In this way, a first molded article 10 is molded between the lower region 24 of the second region 50b of the first mold 03 and the lower region 18 of the B surface 42 of the intermediate mold 05 on the B surface 42. Also, a second molded article 11 is molded between the upper region 25 of the second region 50b in the first surface 50 of the first mold 03 and the upper region 19 of the B surface 42 of the intermediate mold 05. Here, similar to the first step, when the mold is opened after molding, the first molded article 10 and the second molded article 11 remain on the intermediate mold 05.

[0042] In addition, with the first mold member 28 already set in the lower part of the second surface 51 of the second mold 04, the second mold 04 and the intermediate mold 05 are closed, and molten resin is injected into the mold from the injection unit 07. In this way, a third molded article 12 is molded between the lower region 20' of the D surface 44 of the intermediate mold 05 and the region 26.

[0043] At this time, when the mold is opened, the third molded article 12 is left on the second mold 04. The method for leaving the molded article on the second mold 04 is the same as the method for leaving the molded article on the intermediate mold 05 described above. Every time the intermediate mold 05 rotates 90°, the first mold member 28 changes its position in the up and down direction to change the area corresponding to the intermediate mold 05.

[0044] In Figure 6C In the third step shown, the intermediate mold 05 rotates 90° in the direction of arrow α. The first mold member 28 moves to the upper part of the second mold 04. This causes the upper region 16 of the A surface 41 of the intermediate mold 05 where the first molded article 08 and the second molded article 09 are already provided and the region 26 of the second mold 04 where the third molded article 12 is already provided to be set to face each other. After the rotation, by injecting molten resin from the injection unit 07 in the state where the second mold 04 and the intermediate mold 05 are already closed, the first molded article 08, the second molded article 09, and the third molded article 12 are joined together to form a first integral molded article 31 that is molded into a molded finished product. In addition, a third molded article 13 is molded between the region 27 provided in the upper part of the second mold 04 and the upper region 21 of the A surface 41 of the intermediate mold 05.

[0045] On the B surface 42, the elastic member 14 is inserted into the first molded article 10 by using the first assembly robot 29. After inserting the elastic member 14, the second molded article 11 molded on the upper region 19 of the B surface 42 is removed from the intermediate mold 05 by using the first assembly robot 29 and moved to abut and mount on the first molded article 10.

[0046] In addition, in the state where the first mold 03 and the intermediate mold 05 are already closed, molten resin is injected into the mold from the injection unit 06. In this way, on the C surface 43, a first molded article 08 is molded between the upper region 22 of the first region 50a in the first surface 50 of the first mold 03 and the upper region 16' of the C surface of the intermediate mold 05. Moreover, a second molded article 09 is molded between the lower region 23 of the first region 50a and the lower region 17' of the C surface 43 of the intermediate mold 05. When the mold is opened after molding, the first molded article 08 and the second molded article 09 are left on the intermediate mold 05.

[0047] In Figure 6D In the fourth step shown, after the intermediate mold 05 rotates 90° in the direction of arrow α, on the A surface 41, the first integral molded article 31 is taken out by using the second assembly robot 30.

[0048] With the second mold 04 and the intermediate mold 05 already closed, molten resin is injected from the injection unit 07 into the mold, and on the B surface 42, a third molded article 12 is molded between the area 26 that has moved to the lower part of the second mold 04 and the lower area 20 of the B surface 42 of the intermediate mold 05. Additionally, the first molded article 10, the second molded article 11, and the third molded article 13 are joined between the lower area 18 in the first area 42a of the B surface of the intermediate mold 05 and the area 27 provided in the lower part of the second mold 04, such that a second integral molded article 32 is molded, and the second integral molded article becomes the molded product.

[0049] On the C surface 43, the elastic member 14 is inserted into the first molded article 08 molded on the upper area 16 of the A surface 41 of the intermediate mold 05 by using the first assembly robot 29. After inserting the elastic member 14, the second molded article 09 molded on the lower area 17' of the C surface 43 is removed from the intermediate mold 05 by using the first assembly robot 29 and moved to abut against and be mounted on the first molded article 08.

[0050] On the D surface 44, with the first mold 03 and the intermediate mold 05 already closed, molten resin is injected from the injection unit 06 into the mold. In this way, the first molded article 10 is molded between the lower area 24 of the second area 50b of the first mold 03 and the lower area 18' of the D surface 44 of the intermediate mold 05. Moreover, the second molded article 11 is molded between the upper area 25 of the second area 50b in the first surface 50 of the first mold 03 and the upper area 19' of the D surface 44 of the intermediate mold 05. Here, when the mold is opened after molding, the first molded article 10 and the second molded article 11 also remain on the intermediate mold 05.

[0051] By repeating this series of processes, two types of integral molded articles, each composed of a combination of three components, can be alternately molded.

[0052] Figure 7 is a schematic diagram showing the molded articles (the first integral molded article 31 and the second integral molded article 32) molded in Figure 6C the third step and Figure 6D the fourth step. Here, the third step is described as an example.

[0053] In the third step, the third molded article 12 is combined with the assembled first molded article 08 and second molded article 09 to mold a first integral molded article 31. At this time, the third molded article 12 is not taken out from the second mold 04 and the third molded article is combined with the first molded article 08 and the second molded article 09 assembled in the intermediate mold 05 to mold the first integral molded article 31. By not taking out the third molded article 12 from the second mold 04, the molded articles can be assembled without tilting or misalignment.

[0054] As Figure 7 shown, since the second molded article 09 mounted on the first molded article 08 in the second step is taken out of the mold during molding and is mounted by using the first assembly robot 29, there is a case where the second molded article 09 is mounted while being tilted. However, thereafter, by mounting the third molded article 12 without taking it out from the second mold 04, the first integral molded article 31 can be molded in a state where the tilt of the second molded article 09 has been corrected. That is, according to the present embodiment, it is possible to suppress the misalignment or tilt of the components in the gap, thereby increasing the production yield of the molded product compared to the following method in which the second molded article 09 and the third molded article 12 are taken out from the mold in which the second molded article 09 and the third molded article 12 have been molded and the second molded article and the third molded article are mounted on the first molded article 08, as Figure 3 shown.

[0055] Figures 8A to 8E is a schematic view showing the first mold 03, the intermediate mold 05, and the second mold 04 in the first step (see Figure 6A ). Note that Figure 8A the moldings are not shown.

[0056] In the first step, as described above, the first molded article 08 is molded between the upper region 22 of the first region 50a of the first surface 50 of the first mold 03 and the upper region 16 of the A surface 41 of the intermediate mold 05 by using the injection unit 06. Further, the second molded article 09 is molded between the lower region 23 of the first region 50a and the lower region 17 of the second region 41b of the A surface 41 of the A surface of the intermediate mold 05 by using the injection unit 06.

[0057] At this time, the lower region 24 of the second region 50b in the first mold 03 and the upper region 25 of the second region 50b in the first mold 03 do not correspond in terms of the mold parts to the A-surface first region 41a (including the upper region 21) of the A-surface 41 of the facing intermediate mold 05. Specifically, the second region 50b of the first mold 03 is a mold part for molding the first molded article 10 and the second molded article 11 of the second integral molded article 32. However, the upper region 21 of the A-surface 41 of the facing intermediate mold 05 is a mold part for molding the third molded article 13 of the second integral molded article 32. For this reason, this embodiment is configured such that when the molds are closed, the mold parts do not interfere with each other. Specifically, the mold part of the second region 50b of the first mold 03 protrudes more in the mold closing direction than the mold part of the first region 50a. In addition, in the A-surface 41 of the intermediate mold 05, the mold part of the second region 41b protrudes more in the mold closing direction than the mold part of the first region 41a. Then, in the case where the first mold 03 and the intermediate mold 05 are closed with the A-surface 41 of the intermediate mold 05 facing the first mold 03, the mold parts of the first region 50a of the first mold 03 and the second region 41b of the intermediate mold 05 abut against each other. However, the mold parts of the second region 50b of the first mold 03 and the first region 41a of the intermediate mold 05 (non-corresponding molds) are in a separated state. This will be described in detail below.

[0058] Figure 8B is a simplified view of the first mold 03 and the intermediate mold 05 when the mold is open, as viewed in the direction of arrow A. Figure 8C is a simplified view of the first mold 03 and the intermediate mold 05 when the mold is closed, as viewed in the direction of arrow A. In Figure 8B it, the upper mold part 82 and the lower mold part 83 in the first region 50a of the first mold 03 and the upper mold part 84 and the lower mold part 85 in its second region 50b can be seen.

[0059] As Figure 8C shown, when the mold is closed, the upper mold part 82 in the first region 50a of the first mold 03 is combined with the upper mold part 80 in the second region 41b of the A-surface of the intermediate mold 05 to mold the first molded article 08. In addition, the lower mold part 83 in the first region 50a of the first mold 03 is combined with the lower mold part 81 in the second region 41b of the A-surface of the intermediate mold 05 to mold the second molded article 09.

[0060] Figure 8D is a simplified view of the first mold 03 and the intermediate mold 05 when the mold is open, as viewed in the direction of arrow B. Figure 8E is a simplified view of the first mold 03 and the intermediate mold 05 when the mold is closed, as viewed in the direction of arrow B. In Figure 8DIn [description], the upper die member 86 and the lower die member 87 in the first region 41a of the A surface of the intermediate die 05 and the upper die member 80 and the lower die member 81 in the second region 41b of the A surface of the intermediate die 05 can be seen.

[0061] As Figure 8E shown, when the die is closed, the upper die member 84 in the second region 50b of the first die 03 and the upper die member 86 in the first region 41a of the A surface of the intermediate die 05 do not engage with each other. Additionally, the lower die member 85 in the second region 50b of the first die 03 and the lower die member 87 in the first region 41a of the A surface of the intermediate die 05 do not engage with each other.

[0062] Figures 9A to 9E is a simplified diagram showing the first die 03, the intermediate die 05, and the second die 04 in the second step (see Figure 6B ). Note that Figure 9A the die members are not shown.

[0063] In the second step, as described above, the first molded article 10 is molded between the lower region 24 of the second region 50b of the first die 03 and the lower region 18 of the B surface 42 of the intermediate die 05 by using the injection unit 06. Moreover, the second molded article 11 is molded between the upper region 25 of the second region 50b in the first surface 50 of the first die 03 and the upper region 19 of the B surface 42 of the intermediate die 05 by using the injection unit 06.

[0064] At this time, the lower region 23 of the first region 50a in the first die 03 and the upper region 22 of the first region 50a in the first die 03 do not correspond to the second region 42b (including the lower region 20) of the B surface 42 of the intermediate die 05 facing them in terms of die members. For this reason, this embodiment is configured such that the die members do not interfere with each other when the die is closed. Specifically, the die members in the second region 50b of the first die 03 protrude more in the direction of closing the die than the die members in the first region 50a. Additionally, in the B surface 42 of the intermediate die 05, the die members in the first region 42a protrude more in the direction of closing the die than the die members in the second region 41b. Then, in the case where the first die 03 and the intermediate die 05 are closed with the B surface 42 of the intermediate die 05 facing the first die 03, the die members in the second region 50b of the first die 03 and the die members in the first region 41a of the intermediate die 05 abut against each other. However, the die members in the first region 50b of the first die 03 and the die members in the second region 41b of the intermediate die 05 are in a separated state. This will be described in detail below.

[0065] Figure 9B is a simplified diagram showing the first die 03 and the intermediate die 05 when the die is opened as viewed in the direction of arrow C, Figure 9Cis a schematic view of the first mold 03 and the intermediate mold 05 when the mold is closed, as viewed in the direction of arrow C. In Figure 9B it, the upper mold member 82 and the lower mold member 83 in the first region 50a of the first mold 03 and the upper mold member 84 and the lower mold member 85 in the second region 50b can be seen. Additionally, the upper mold member 90 and the lower mold member 91 in the second region 42b of the B surface 42 of the intermediate mold 05 and the upper mold member 96 and the lower mold member 97 in the first region 42a of its B surface can be seen.

[0066] As Figure 9C shown, when the mold is closed, the upper mold member 84 in the second region 50b of the first mold 03 and the upper mold member 96 in the first region 42a of the B surface of the intermediate mold 05 are combined to mold the second molded product 11. Additionally, the lower mold member 85 in the second region 50b of the first mold 03 and the lower mold member 97 in the first region 42a of the B surface of the intermediate mold 05 are combined to mold the first molded product 10. At this time, the upper mold member 82 in the first region 50a of the first mold 03 and the upper mold member 90 in the second region 42b of the B surface 42 of the intermediate mold 05 do not engage with each other. Additionally, the lower mold member 83 in the first region 50a of the first mold 03 and the lower mold member 91 in the second region 42b of the B surface 42 of the intermediate mold 05 do not engage with each other.

[0067] Figure 9D is a schematic view of the first mold 03 and the intermediate mold 05 when the mold is opened, as viewed in the direction of arrow D, Figure 9E is a schematic view of the first mold 03 and the intermediate mold 05 when the mold is closed, as viewed in the direction of arrow D. In Figure 9D it, the upper mold member 96 and the lower mold member 97 in the first region 42a of the B surface and the upper mold member 84 and the lower mold member 85 in the second region 50b of the first mold 03 can be seen.

[0068] As Figure 9E shown, when the mold is closed, the upper mold member 96 in the first region 42a of the B surface is combined with the upper mold member 84 in the second region 50b of the first mold 03. Additionally, the lower mold member 97 in the first region 42a of the B surface and the lower mold member 85 in the second region 50b of the first mold 03 are combined. In this way, in the case where non-corresponding mold members face each other, the positions of the mold surfaces are appropriately shifted along the direction of mold opening and closing so that the mold members should not interfere with each other when the mold is closed.

[0069] In this way, the first mold 03 is divided into a first region 50a and a second region 50b, and each of the surfaces from the A surface to the D surface of the intermediate mold 05 is divided into a first region and a second region. Moreover, in the second mold 04, the moldings are configured to be movable between an upper portion (first position) and a lower portion (second position). This makes it possible to provide a molded product manufacturing method and manufacturing equipment capable of performing more complex molding.

[0070] (Variant)

[0071] Hereinafter, a variant of the first embodiment of the present disclosure will be described with reference to the accompanying drawings.

[0072] Figures 10A to 10D is a schematic diagram showing the molding process in the variant. Compared with the first embodiment capable of alternately repeating the molding of two integral molded products, this variant repeats the molding of one integral molded product. Hereinafter, the molding process in this embodiment will be described in the order of steps. Note that since the molding process is continuously and simultaneously implemented, the process based on the A surface 41 of the intermediate mold 05 will be described here, while referring to the other surfaces (B surface 42, C surface 43, and D surface 44).

[0073] In Figure 10A In the first step shown, in a state where the first mold 03 and the intermediate mold 05 are closed, molten resin is injected into the mold from the injection unit 06. In this way, a first molded product 08 is molded between the upper region 22 of the first region 50a in the first surface 50 of the first mold 03 and the upper region 16 of the A surface 41 of the intermediate mold 05. Moreover, a second molded product 09 is molded between the lower region 23 of the first region 50a and the lower region 17 of the second region 41b of the A surface 41 of the intermediate mold 05. When the mold is opened after molding, the first molded product 08 and the second molded product 09 remain on the intermediate mold 05.

[0074] In Figure 10B In the second step shown, after the intermediate mold 05 is rotated 90 degrees in the direction of arrow α, the elastic member 14 is inserted into the first molded product 08 molded on the upper region 16 of the A surface 41 of the intermediate mold 05 by using the first assembly robot 29. After inserting the elastic member 14, the second molded product 09 molded on the lower region 17 of the A surface 41 is removed from the intermediate mold 05 by using the first assembly robot 29 and moved to abut against and be mounted on the first molded product 08.

[0075] On the D surface 44, the molten resin is injected into the mold in a state where the second mold 04 and the intermediate mold 05 have been closed. Thus, the third molded article 12' is molded between the region 26 in the case where the first mold member 28 is provided in the lower part of the second surface 51 of the second mold 04 and the lower region 20' of the D surface 44 of the intermediate mold 05.

[0076] At this time, when the mold is opened, the third molded article 12' remains on the second mold 04. Whenever the intermediate mold 05 rotates 90°, the first mold member 28 changes its position in the vertical direction to change the region corresponding to the intermediate mold 05.

[0077] In Figure 10C In the third step shown, the intermediate mold 05 rotates 90° in the direction of arrow α. Then, in a state where the first mold 04 and the intermediate mold 05 have been closed, the molten resin is injected into the mold. Thus, by using the upper region 16 in the second region 41b of the A surface of the intermediate mold 05 and the region 26 in the case where the first mold member 28 is provided in the upper part of the second mold 04, the third molded article 12' is combined with the installed first molded article 08 and second molded article 09 to mold the first integral molded article 31.

[0078] On the C surface 43, the molten resin is injected into the mold in a state where the first mold 03 and the intermediate mold 05 have been closed. Thus, the first molded article 08 is molded between the upper region 22 of the first region 50a in the first surface 50 of the first mold 03 and the upper region 16' of the C surface 43 of the intermediate mold 05. Moreover, the second molded article 09 is molded between the lower region 23 of the first region 50a and the lower region 17' of the C surface 43 of the intermediate mold 05. When the mold is opened after molding, the first molded article 08 and the second molded article 09 remain on the intermediate mold 05.

[0079] In Figure 10D In the fourth step shown, after the intermediate mold 05 rotates 90° in the direction of arrow α, on the A surface 41, the first integral molded article 31 is taken out by using the second assembly robot 30.

[0080] The molten resin is injected into the mold in a state where the second mold 04 and the intermediate mold 05 have been closed. Thus, on the B surface 42, the third molded article 12' is molded between the region 26 in the case where the first mold member 28 is provided in the lower part on the second surface 51 of the second mold 04 and the lower region 20 of the B surface 42 of the intermediate mold 05.

[0081] On the C surface 43, the elastic member 14 is inserted into the first molded article 08 molded on the upper region 16 of the A surface 41 of the intermediate mold 05 by using the first assembly robot 29. After the elastic member 14 is inserted, the second molded article 09 molded on the lower region 17' of the C surface 43 is removed from the intermediate mold 05 and moved to abut against and mounted on the first molded article 08 by using the first assembly robot 29.

[0082] In this way, a type of integral molded article can be repeatedly molded by the method of this variant.

[0083] (Other embodiments)

[0084] Although in the first embodiment, such a configuration has been described by way of example, in which both the first integral molded article 31 and the second integral molded article 32 are obtained by molding and combining the first molded article, the second molded article, and the third molded article, the configuration is not limited thereto. The following configurations are also feasible, in which, instead of molding the third molded article, the first molded article and the second molded article are molded and combined to mold the integral molded article. That is, the first integral molded article 31 may be configured to include the first molded article 08 and the second molded article 09 without including the third molded article 12, and the second integral molded article 32 may be configured to include the first molded article 10 and the second molded article 11 without including the third molded article 13.

[0085] Although the present disclosure has been described with reference to exemplary embodiments, it should be understood that the present disclosure is not limited to the disclosed exemplary embodiments. The broadest interpretation should be given to the following claims to cover all such variations and equivalent structures and functions.

Claims

1. A method for manufacturing a molded article, the method for manufacturing a molded article using: a first mold having a first surface; a second mold having a second surface; and an intermediate mold having surfaces A, B, C, and D, each surface being capable of facing the first surface and the second surface, the intermediate mold being capable of changing the surface facing the first surface and the second surface by rotating between the first mold and the second mold; the method for manufacturing a molded article comprising: a first molding step: molding a first component and a second component between the first surface and surface A by closing the first mold and the intermediate mold with surface A facing the first surface and injecting molten resin into the mold; a second molding step: molding a third component and a fourth component between the first surface and surface B by closing the first mold and the intermediate mold with surface B facing the first surface and injecting molten resin into the mold, and causing the second component to join with the first component held on surface A; a third molding step: welding the first component and the second component to mold a first integral molded article by closing the second mold and the intermediate mold with surface A facing the second surface and injecting molten resin into the mold, and causing the fourth component to join with the third component held on surface B; and a fourth molding step: welding the third component and the fourth component to mold a second integral molded article different from the first integral molded article by closing the second mold and the intermediate mold with surface B facing the second surface and injecting molten resin into the mold.

2. The method for manufacturing a molded article according to claim 1, wherein the mold part of surface C is the same as the mold part of surface A, and the mold part of surface D is the same as the mold part of surface B, in the second molding step, a fifth component is molded between the second surface and surface D by closing the second mold and the intermediate mold with surface D facing the second surface and injecting molten resin into the mold formed by a first region of the second surface and a partial region of surface D. In the third molding step, the first member and the second member are molded between the first surface and the C surface by closing the first mold and the intermediate mold with the C surface facing the first surface and injecting molten resin into the mold. Further, the first member, the second member, and the fifth member are welded by closing the second mold and the intermediate mold with the A surface facing the second surface and injecting molten resin into the mold to mold the first integral molded article. The A surface holds the first member and the second member joined to each other in the second molding step, and the second surface holds the fifth member molded in the second molding step. In the fourth molding step, the third member and the fourth member are molded between the first surface and the D surface by closing the first mold and the intermediate mold with the D surface facing the first surface and injecting molten resin into the mold, and in the fourth molding step, the first integral molded article is removed from the intermediate mold.

3. The method for manufacturing a molded article according to claim 2, wherein, In the second surface, the first region and the second region adjacent to the first region can move to a first position and a second position in a state of being adjacent to each other.

4. The method for manufacturing a molded article according to claim 3, wherein, The first region and the second region move as the intermediate mold rotates.

5. The method for manufacturing a molded article according to claim 1, wherein, in the second molding step, the second member is joined to the first member by a robot, and in the third molding step, the fourth member is joined to the second member by the robot.

6. The method for manufacturing a molded article according to claim 5, wherein, in the second molding step, the robot inserts a first member between the first member and the second member, and in the third molding step, the robot inserts a second member between the third member and the fourth member.

7. The method for manufacturing a molded article according to claim 6, wherein, The first member and the second member are elastic members.

8. The method for manufacturing a molded article according to claim 1, wherein, the resin for welding the first member and the second member in the third molding step is a resin different from the materials of the first member and the second member, and the resin for welding the third member and the fourth member in the fourth step is a resin different from the materials of the third member and the fourth member.

9. A method for manufacturing a molded article, the method for manufacturing a molded article using: a first mold having a first surface; a second mold having a second surface; and an intermediate mold having an A surface, a B surface, a C surface, and a D surface, each surface being capable of facing the first surface and the second surface, and the intermediate mold being capable of changing the surface facing the first surface and the second surface by rotating between the first mold and the second mold, the method for manufacturing a molded article includes: First molding step: By closing the first mold and the intermediate mold with the first surface facing the first mold and injecting molten resin into the mold, a first component and a second component are molded between the first mold and the first surface; Second molding step: By closing the second mold and the intermediate mold with the D surface facing the second surface and injecting molten resin into the mold, a fifth component is molded between the second surface and the D surface, and the second component is joined to the first component held on the A surface; Third molding step: By closing the second mold and the intermediate mold with the A surface facing the second surface and injecting molten resin into the mold, the first component, the second component, and the fifth component are welded to mold a first integral molded article. The A surface holds the first component and the second component joined to each other in the second molding step, and the second surface holds the fifth component molded in the second molding step.

10. The method for manufacturing a molded article according to claim 9, wherein In the second molding step, by closing the first mold and the intermediate mold with the B surface facing the first surface and injecting molten resin into the mold, a third component and a fourth component are molded between the first surface and the B surface, In the third molding step, by closing the first mold and the intermediate mold with the A surface facing the second surface and injecting molten resin into the mold, a sixth component is further molded between the first surface and the A surface, and the fourth component is joined to the third component held on the B surface, The method for manufacturing a molded article further includes: Fourth molding step: By closing the second mold and the intermediate mold with the B surface facing the second surface and injecting molten resin into the mold, the third component, the fourth component, and the sixth component are welded to mold a second integral molded article different from the first integral molded article. The B surface holds the third component and the fourth component joined to each other in the third molding step, and the second surface holds the sixth component molded in the third molding step, and In the fourth molding step, the first integral molded article is removed from the intermediate mold.

11. A manufacturing apparatus, the manufacturing apparatus includes: A first mold, the first mold being connected to a first injection unit for injecting resin and having a first surface; A second mold, the second mold being connected to a second injection unit for injecting resin and having a second surface; And An intermediate mold, the intermediate mold being disposed between the first mold and the second mold and having four surfaces, namely an A surface, a B surface, a C surface, and a D surface, each surface being capable of facing the first surface and the second surface, wherein, Modules are provided on the first surface and the A surface, and the modules can mold a first component and a second component by closing in a state where they are made to face each other and injecting molten resin from the first injection unit. Modules are provided on the first surface and the B surface, and the modules can mold a third component and a fourth component by closing in a state where they are made to face each other and injecting molten resin from the first injection unit. Modules are provided on the second surface, and the modules can weld the first component and the second component by closing in a state where they are made to face the A surface and injecting molten resin from the second injection unit to mold a first integral molded product, and Modules are provided on the second surface, and the modules can weld the third component and the fourth component by closing in a state where they are made to face the B surface and injecting molten resin from the second injection unit to mold a second integral molded product, which is different from the first integral molded product.

12. A manufacturing apparatus, the manufacturing apparatus comprising: A first mold connected to a first injection unit for injecting resin and having a first surface; A second mold connected to a second injection unit for injecting resin and having a second surface; And An intermediate mold disposed between the first mold and the second mold and having four surfaces, namely an A surface, a B surface, a C surface, and a D surface, each of which can face the first surface and the second surface, wherein Modules are provided on the first surface and the A surface, and the modules can mold a first component and a second component by closing in a state where they are made to face each other and injecting molten resin into the mold. Modules are provided on the second surface and the D surface, and the modules mold a fifth component by closing in a state where they are made to face each other and injecting the molten resin into the mold. Modules are provided on the second surface and the A surface holding the fifth component, and the modules can weld the first component, the second component, and the fifth component by closing in a state where the A surface and the second surface face each other and injecting molten resin into the mold to mold a first integral molded product, and the A surface holds the first component and the second component joined to each other.

13. The manufacturing apparatus according to claim 12, wherein Modules that close and mold the first component and the second component in a case of closing in a state where they are made to face each other and non-corresponding modules that do not close and are separated are provided on the first surface and the A surface.

14. The manufacturing apparatus according to claim 12, wherein Modules are provided on the second surface and the A surface, and the modules can mold a sixth component by closing in a state where they are made to face each other and injecting molten resin into the mold. Modules are provided on the second surface of the sixth member and the A surface, and the modules can be closed in a state where the B surface faces the second surface and the third member, the fourth member, and the sixth member are welded by injecting molten resin into the mold to mold a third integral molded article, and the B surface holds the third member and the fourth member that are joined to each other.

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