Resin molding apparatus and method for manufacturing resin molded article

Abstract

A resin molding apparatus includes: a storage portion that stores workpieces; an alignment mechanism that aligns the workpieces; a conveyance mechanism that conveys the workpieces from the storage portion to the alignment mechanism; and a molding die that molds the workpieces conveyed from the alignment mechanism. The conveyance mechanism includes: a carrying member that has a carrying surface on which the workpieces are placed; and a moving mechanism that moves the carrying member on which the workpieces are placed in a state where the workpieces are placed on the carrying surface from a first position to a second position. The carrying member receives the workpieces from the storage portion to the carrying surface at the first position, and is disposed in the alignment mechanism together with the workpieces at the second position.

Description

Technical Field

[0001] This invention relates to a resin molding apparatus and a method for manufacturing resin molded articles. Background Technology

[0002] Patent Document 1 discloses a resin molding apparatus. In this apparatus, a workpiece to be resin molded is pushed out from a receiving section called a feed box and moved to an aligning mechanism disposed adjacent to the feed box.

[0003] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2020-121463 The aligning mechanism is positioned a certain distance away from the workpiece outlet in the feed box. Therefore, the workpiece needs to be moved from near the outlet of the feed box to the aligning mechanism in some way. This is not explicitly described in Patent Document 1, but conventionally, for example, a clamping mechanism is positioned near the outlet of the feed box. The clamping mechanism holds the workpiece pushed out from the outlet of the feed box and moves it to the aligning mechanism by pulling.

[0004] However, due to the different types of workpieces, sufficient rigidity cannot always be ensured. Examples of such workpieces include lead frames made of materials lacking rigidity and prone to bending, and / or lead frames with numerous punches. For such workpieces, from a workpiece protection perspective, slow transport is often necessary from the time they leave the feed box until they reach the alignment mechanism. This is because high-speed transport of such workpieces could lead to deformation such as bending or twisting during transport, or even detachment from the transport path. However, this would prevent a significant increase in the production speed of resin molded products, potentially reducing the number of resin molded products produced per unit time. Summary of the Invention

[0005] The purpose of this invention is to provide a resin molding apparatus and a method for manufacturing resin molded articles that can increase the production quantity of resin molded articles per unit time.

[0006] According to one aspect of the present invention, a resin molding apparatus includes: a receiving section for receiving workpieces; an aligning mechanism for aligning workpieces; a conveying mechanism for transferring workpieces from the receiving section to the aligning mechanism; and a molding die for resin molding workpieces transferred from the aligning mechanism. The conveying mechanism includes: a carrying member having a mounting surface for placing workpieces; and a moving mechanism for moving the carrying member, in a state where a workpiece is placed on the mounting surface, from a first position to a second position. In the first position, the carrying member receives the workpiece from the receiving section to the mounting surface, and in the second position, the workpiece is disposed together with the workpiece on the aligning mechanism.

[0007] According to another aspect of the present invention, a method for manufacturing a resin molded article includes: using the above-described resin molding apparatus to perform resin molding on a workpiece in a molding die to manufacture a resin molded article.

[0008] Invention Effects According to the present invention, a resin molding apparatus and a method for manufacturing resin molded articles are provided that can increase the production quantity of resin molded articles per unit time. Attached Figure Description

[0009] Figure 1 This is a schematic top view of a resin molding apparatus according to one embodiment.

[0010] Figure 2A This is a top view of the surroundings of the conveying mechanism involved in one embodiment.

[0011] Figure 2B They are from different times. Figure 2A A top view of the area surrounding the conveyor system.

[0012] Figure 2C It is yet another different moment. Figure 2A A top view of the area surrounding the conveyor system.

[0013] Figure 2D It is yet another different moment. Figure 2A A top view of the area surrounding the conveyor system.

[0014] Figure 2E It is yet another different moment. Figure 2A A top view of the area surrounding the conveyor system.

[0015] Figure 2F It is yet another different moment. Figure 2A A top view of the area surrounding the conveyor system.

[0016] Figure 2G It is yet another different moment. Figure 2A A top view of the area surrounding the conveyor system.

[0017] Figure 2H It is yet another different moment. Figure 2A A top view of the area surrounding the conveyor system.

[0018] Figure 2I It is yet another different moment. Figure 2A A top view of the area surrounding the conveyor system.

[0019] Figure 3 yes Figure 2D Sectional view along line III-III.

[0020] Figure 4This is a cross-sectional view of the supporting component and the moving mechanism according to one embodiment.

[0021] Figure 5 yes Figure 2A VV-line sectional view.

[0022] Explanation of reference numerals in the attached figures 100: Resin molding device; 1: Control unit; 2: Molding mechanism; 3: Conveying mechanism; 4: Alignment mechanism; 5: Loader; 5a: Pick-up mechanism; 6: Unloader; 6a: Pick-up mechanism; 7: Feed box; 8: Discharge box; 9: Touch panel; 20: Molding mold; 30: Bearing component; 30A: Recess; 31: Flat plate; 31A: Track groove; 31B: Insertion port; 31C: Hollowed-out part; 32, 33, 34: Protrusion; 40: Rotary disk; 41: Support mechanism; 42: Support plate; 42A: Track; 43, 44: Side wall; 43A, 44A: Protruding piece; 45: Force-applying component; 46, 47: Rod-shaped component; 50: Moving mechanism; 51: Guide component; 52: Connecting component; 521: Main... Body; 522: Insertion component; 523: Lifting mechanism; 53: Actuator; 60: Ejection mechanism; 61: Guide; 62: Push rod; 62A: Hollowed-out part; 63: Actuator; 70: Resin supply mechanism; 80: Guide mechanism; 81: Support plate; 82: Side wall; 821: First step part; 822: Second step part; 822A: Inclined surface; 83: Recess; B1, B2: Cutouts; C1: Placement surface; C2: Placement surface; M1: Feeding module; M2: Molding module; M3: Discharge module; G: Guide; W1: Workpiece (molding object); W2: Workpiece (resin molded article); T: Resin material; P1: First position; P2: Second position; P3: Third position; P4: Fourth position. Detailed Implementation

[0023] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings. Furthermore, in the drawings, the same or equivalent parts are labeled with the same reference numerals, and their descriptions are omitted. Additionally, for ease of understanding, the objects depicted in the drawings are appropriately omitted or exaggerated schematically.

[0024] <1. Overall Structure of the Resin Molding Device> Figure 1This is a schematic top view of the resin molding apparatus 100 according to this embodiment. The resin molding apparatus 100 uses resin material T to resin mold a workpiece W1, which is the object to be molded. In the description here, the workpiece W1 is exemplified by a thin plate-shaped substrate to which electronic components such as semiconductor chips are fixed. The resin molding apparatus 100 is suitable for processing workpieces W1 formed into thin plates, and is particularly suitable for processing workpieces W1 with low rigidity that are prone to bending, twisting, or other deformations. Examples of such workpieces W1 include lead frames, especially lead frames with materials lacking rigidity that are prone to bending and / or lead frames with many punches.

[0025] The resin molding apparatus 100 includes a feeding module M1, a molding module M2, and a discharging module M3. These modules M1 to M3 are connected in this order to form an integrated device. Figure 1 Two molding modules M2 are shown, but there can be only one molding module M2 or more. Molding module M2 includes a molding mechanism 2. The molding mechanism 2 uses resin material T to seal electronic components fixed to workpiece W1, performing resin molding to process workpiece W1 into workpiece W2 as a resin molded product. Feeding module M1 includes: a feeding box 7 (an example of a receiving section) for storing multiple workpieces W1 before resin molding; and a resin supply mechanism 70. The resin supply mechanism 70 is a device for supplying resin material T. Discharging module M3 includes a discharging box 8 for storing multiple resin-molded workpieces W2.

[0026] The feeding module M1 also includes an aligning mechanism 4 adjacent to the feeding box 7 and a conveying mechanism 3 for moving the workpiece W1 from the feeding box 7 to the aligning mechanism 4. The conveying mechanism 3 includes a carrying component 30, a moving mechanism 50, and an ejection mechanism 60. The moving mechanism 50 causes the carrying component 30 to... Figure 1 The first position P1 shown by the dashed line is... Figure 1 The device reciprocates between the second position P2, indicated by the solid line. The first position P1 is closer to the feed box 7 than the second position P2. When the carrying member 30 is positioned at the first position P1, the ejection mechanism 60 ejects the workpiece W1 from the feed box 7 and transfers it to the carrying member 30. That is, the carrying member 30 receives the workpiece W1 from the feed box 7 at the first position P1. Figure 1 The workpiece W1, held on the support member 30 positioned at the first position P1, is also shown in dashed lines. Then, the moving mechanism 50 moves the support member 30, which holds the workpiece W1, from the first position P1 to the second position P2.

[0027] The aligning mechanism 4 is for aligning workpieces W1 and has a rotating disk 40 that can rotate in a horizontal plane. A second position P2 is provided on the rotating disk 40. Therefore, when the moving mechanism 50 moves the carrying member 30, which holds workpiece W1, to the second position P2, the workpiece W1 is positioned at a predetermined location on the rotating disk 40. Figure 1 As shown, the aligning mechanism 4 can simultaneously carry two carrier components 30. When two workpieces W1 are placed on the rotary table 40 together with the carrier components 30, the rotary table 40 rotates to a position suitable for being picked up by the loader 5 described later, thus aligning the workpieces W1.

[0028] The resin molding apparatus 100 also includes a guide G extending in the left-right direction, and a loader 5 and an unloader 6 moving along the guide G. Furthermore, unless otherwise specified, in the description of this embodiment, front (front), rear (back), left, right, top, and bottom are as follows: Figures 1-5 As defined, the guide G is the track for the loader 5 and unloader 6 to travel on. The guide G is arranged in a straight line across the feeding module M1, molding modules M2, M3 and discharging module M3 along the rear side of the resin molding apparatus 100. The molding mechanism 2, conveying mechanism 3, aligning mechanism 4, resin supply mechanism 70, feeding box 7 and discharging box 8 are arranged on the front side relative to the guide G.

[0029] The loader 5 is a loading mechanism that moves the workpiece W1 and resin material T into the molding die 20. The molding dies 20 are arranged one by one in the molding mechanisms 2, 2. The loader 5 has a picking mechanism 5a for picking up the workpiece W1 and resin material T. The picking mechanism 5a can move forward and backward in the front-to-back direction and can move up and down in the vertical direction. The loader 5 moves along the guide G between the feeding module M1 and the molding modules M2, M2. Thus, the picking mechanism 5a can access the aligning mechanism 4 and the resin supply mechanism 70 in the feeding module M1, and the molding die 20 in the molding module M2. The picking mechanism 5a has multiple pairs of claws, which grip and pick up the workpiece W1 from the aligning mechanism 4, and transport it to and place it on the lower mold of the molding die 20, but is not limited to this. In addition, the picking mechanism 5a has a shutter, through which the resin material T supplied by the resin supply mechanism 70 located below is held and received from below. Then, the picking mechanism 5a transports the received resin material T to the lower mold of the molding die 20, opens the gate, and supplies it to the material cylinder (a space for temporary storage of resin material T) of the lower mold of the molding die 20.

[0030] The molding die 20 is a die used to resin mold the workpiece W1, which is transported from the aligning mechanism 4 by the loader 5, using resin material T, which is also transported from the resin supply mechanism 70 by the loader 5. The molding die 20 is a metal die having an upper and lower pair of molds, but is not limited to this. When the workpiece W1 and the resin material T are placed in a predetermined position within the lower mold by the loader 5, the upper and lower molds are closed. Furthermore, the upper and lower molds are heated, and the resin material T in the barrel melts. The molten resin material T is pushed out of the barrel by a plunger into a cavity formed between the upper and lower molds, where it hardens while covering the electronic components on the workpiece W1. Thus, the workpiece W1 is resin molded, producing the workpiece W2 (an example of a resin-molded article). While transfer molding is illustrated here, different molding methods such as compression molding can also be used.

[0031] The unloading machine 6 is a conveying mechanism that removes the resin-molded workpiece W2 from the molding die 20. The unloading machine 6 includes a picking mechanism 6a for picking up the workpiece W2. The picking mechanism 6a can move forward and backward in the front-to-back direction and can move up and down in the rear-to-rear direction. The unloading machine 6 moves along the guide G between the discharge module M3 and the molding modules M2. Thus, the picking mechanism 6a can approach the discharge box 8 in the discharge module M3 and the molding die 20 in the molding module M2. Like the picking mechanism 5a, the picking mechanism 6a also has multiple pairs of claws, which grip and pick up the workpiece W2 from the lower mold of the molding die 20, and transport it to the discharge box 8 for storage, but is not limited to this.

[0032] The resin molding apparatus 100 includes a control unit 1 that controls the operation of each component. The control unit 1 includes a CPU (central processing unit), ROM (read-only memory), RAM (random access memory), and non-volatile memory. The CPU executes a control program stored in the non-volatile memory and / or ROM, thereby executing the operation of each component. Furthermore, the resin molding apparatus 100 includes a user interface device such as an input device and a display device; in this embodiment, it is implemented as a touch panel 9. However, the control unit 1 and the touch panel 9 are not limited to... Figure 1 The position can be set anywhere.

[0033] <2. The structure surrounding the conveying mechanism> Reference Figures 2A to 2I and Figure 3 The structure surrounding the conveying mechanism 3 involved in this embodiment will be described in detail. Figures 2A to 2I This is a top view of the conveying mechanism 3, showing the flow of its conveying actions in sequence. Figures 2A to 2I In addition to the conveying mechanism 3, the diagram also shows the feeding box 7 and the aligning mechanism 4. Figure 3 yes Figure 2D Sectional view along line III-III.

[0034] like Figures 2A to 2I and Figure 3 As shown, two support mechanisms 41 are arranged on the upper surface of the rotating disk 40 included in the alignment mechanism 4. Each of these support mechanisms 41 mounts a support member 30. These support mechanisms 41 are fixed relative to the rotating disk 40 and rotate as the rotating disk 40 rotates. These support mechanisms 41 have a structure that is approximately point-symmetrical with respect to the rotation center of the rotating disk 40. Therefore, for simplicity, the structure of one support mechanism 41 will be described below, but the other support mechanism 41 also has the same (approximately point-symmetrical) structure. Furthermore, since the two support members 30 mounted on the two support mechanisms 41 also have the same structure, only one support member 30 will be described below.

[0035] The support mechanism 41 has a support plate 42 that is generally rectangular in plan view and side walls 43 and 44 respectively disposed at both ends of the support plate 42 in the direction of its short side. The side walls 43 and 44 protrude upward from the upper surface of the support plate 42. In addition, among the side walls 43 and 44, the one closer to the rotation center of the rotating disk 40 is designated as 43, and the one farther from the rotation center of the rotating disk 40 is designated as 44. A track 42A extending in the length direction is disposed on the upper surface of the support plate 42. On the other hand, the carrying member 30 included in the conveying mechanism 3 has a plate 31 that is generally rectangular in plan view, and a track groove 31A extending in the length direction is formed on the lower surface of the plate 31. The track 42A is embedded in the track groove 31A. A component with good sliding properties, such as a bearing, is preferably disposed between the track groove 31A and the track 42A. As described above, the carrying member 30 is supported from below by the support plate 42 and is configured to slide along the length direction on the support plate 42. In addition, the number of sets of rails 42A and rail grooves 31A provided on a set of support mechanisms 41 and bearing components 30 is... Figure 3 In this example, there are two sets, but it is not limited to this. Alternatively, a track can be provided on the bearing component 30, and a track groove can be formed on the support mechanism 41.

[0036] The supporting member 30 has protrusions 33 and 34 respectively disposed at both ends of the short side of the plate 31. The protrusions 33 and 34 protrude upwards from the upper surface of the plate 31. The protrusions 33 and 34 extend slightly inside and parallel to the sidewalls 43 and 44 included in the support mechanism 41. The upper surfaces of the protrusions 33 and 34 are at the same height. As a result, a mounting surface C1 for mounting the workpiece W1 is formed on the upper surface of the supporting member 30 (see reference). Figure 3The mounting surface C1 is a virtual surface that includes the upper surfaces of the protrusions 33 and 34. Additionally, in this embodiment, the supporting member 30 also has a protrusion 32 that protrudes upward from the upper surface of the plate 31. The protrusion 32 is disposed at the center of the short side of the plate 31 and extends parallel to the protrusions 33 and 34. The upper surface of the protrusion 32 is at the same height as the upper surfaces of the protrusions 33 and 34, and the mounting surface C1 includes the upper surface of the protrusion 32 in addition to the upper surfaces of the protrusions 33 and 34. Furthermore, the upper surface of the protrusion 32 does not necessarily have to be at the same height as the upper surfaces of the protrusions 33 and 34; the height may be consistent depending on the degree of warping or deflection of the workpiece W1, or it may not be.

[0037] A recess 30A is provided on the mounting surface C1 to reduce the contact area between the support member 30 and the workpiece W1 when the workpiece W1 is mounted. That is, in this embodiment, the workpiece W1 does not contact the support member 30 except for the upper surfaces of the protrusions 32-34. The recess 30A is formed between the protrusions 32-34 and is a space recessed downward from the upper surfaces of the protrusions 32-34. Therefore, due to the recess 30A, the contact area between the workpiece W1 and the object (support member 30) is reduced, reducing the risk of damage or deformation of the workpiece W1 due to friction with the object (support member 30). In addition, in this embodiment, the protrusions 32 are fixed to the plate 31 in a detachable manner. Therefore, depending on the type of workpiece W1, by removing the protrusions 32 or replacing them with protrusions of other shapes, the parts of the workpiece W1 that are particularly desired to be protected can be appropriately protected.

[0038] Side walls 43 and 44 are respectively disposed slightly outside the protrusions 33 and 34, and protrude upwards further than the protrusions 33 and 34. Therefore, it is possible to prevent the workpiece W1 from shifting position on the support member 30 along the width direction (the direction of the short side of the plate 31). In particular, even when the support member 30 slides on the support plate 42 while the workpiece W1 is mounted, or when the rotating disk 40 carrying the support member 30 on which the workpiece W1 is mounted rotates, the workpiece W1 will not shift position on the support member 30 due to vibration or inertial forces. Therefore, it is also possible to prevent the workpiece W1 from falling off the support member 30. Furthermore, in this embodiment, protruding pieces 43A and 44A that slightly protrude towards the protrusions 33 and 34 (see reference) are provided at the upper ends of the side walls 43 and 44. Figure 3 By setting such protruding pieces 43A and 44A, the upward warping of workpiece W1 can be suppressed.

[0039] Side walls 43 and 44 can move closer to or further apart from each other. Figure 3In the diagram, the closest states of sidewalls 43 and 44 are represented by solid lines, and the furthest states by dashed lines. The support mechanism 41 has a force-applying member 45, including a spring. The sidewalls 43 and 44 are forceped by the force-applying member 45 from the outside towards each other; in other words, force is applied towards the inner sides of the protrusions 33 and 34, respectively. On the other hand, rod-shaped members 46 and 46 extending inward are connected to the lower portions of the sidewalls 43 and 44, respectively. The inner ends of the rod-shaped members 46 and 46 contact a rod-shaped member 47 extending in a direction orthogonal to the rod-shaped members 46 and 46. The rod-shaped member 47 is driven by an actuator (not shown) controlled by the control unit 1, and oscillates in the length direction. The rod-shaped member 47 has a cam whose diameter smoothly varies along the length direction, and the inner ends of the rod-shaped members 46 and 46 contact this cam. When the inner ends of the rod-shaped members 46 and 46 contact the portion of the cam with the smallest diameter... Figure 3 When (shown by solid lines), sidewalls 43 and 44 are closest to each other. On the other hand, when the inner ends of rod-shaped components 46 and 46 contact the portion of the cam with its maximum diameter (…),… Figure 3 When the workpiece W1 is received from the feed box 7 onto the mounting surface C1 by the support member 30 (indicated by dashed lines), the side walls 43 and 44 are most separated. The control unit 1 makes the side walls 43 and 44 most separated when the workpiece W1 is received onto the mounting surface C1 by the support member 30. Then, when the workpiece W1 is placed on the mounting surface C1, the control unit 1 brings the side walls 43 and 44 closest together. Therefore, even if the workpiece W1 is slightly offset in the width direction (short side direction of the plate 31) when received onto the mounting surface C1, it will be pushed inward by the side walls 43 and 44, thus being more accurately aligned along the width direction on the support member 30.

[0040] The side walls 43 and 44 have several cuts along their length, and the protrusions 33 and 34 also have several cuts along their length. For example... Figure 2A As shown, the cut on the side wall 43 is aligned along the length direction with the cut on the protrusion 33 arranged parallel to the side wall 43, forming a cut B1. Similarly, the cut on the side wall 44 is aligned along the length direction with the cut on the protrusion 34 arranged parallel to the side wall 44, forming a cut B2. When the multiple pairs of claws of the loader 5's picking mechanism 5a pick up the workpiece W1 on the mounting surface C1, they are inserted into these cuts B1 and B2 from the outside.

[0041] A cutout portion 31C is appropriately formed on the flat plate 31. The support component 30 achieves weight reduction through the cutout portion 31C. The cutout portion 31C can be a through hole or a bottomed opening.

[0042] The moving mechanism 50 moves the bearing component 30 to the first position P1 (see reference). Figure 2C (etc.) and the second position P2 (refer to) Figure 2D It moves back and forth between (etc.). For example... Figures 2A to 2IAs shown, the moving mechanism 50 has a guide 51, a connecting member 52 that moves along the guide 51, and an actuator 53 (drive source) that drives the connecting member 52 to move along the guide 51. The guide 51 extends from near a first position P1 to near a second position P2 in top view. The actuator 53 is implemented, for example, by a servo motor. In this case, the guide 51 is implemented, for example, as a ball screw connected to the output shaft of the servo motor.

[0043] Figure 4 A cross-sectional view of the support member 30 and the moving mechanism 50 is shown. As shown in the figure, the guide member 51 and the connecting member 52 are disposed above the support member 30. The connecting member 52 is detachably connected to the support member 30. More specifically, as... Figure 4 As shown, an insertion port 31B is formed on the upper surface of the plate 31 included in the support member 30. The insertion port 31B can be a through hole or a bottomed opening. On the other hand, the connecting member 52 has an insertion member 522. The insertion member 522 is inserted into the insertion port 31B in a manner that connects the support member 30 and the connecting member 52. In addition, Figure 4 This is a cross-sectional view taken through the insertion port 31B and parallel to the short side of the plate 31, showing the state in which the insertion member 522 is inserted into the insertion port 31B. The insertion member 522 can have any shape that can be detached from the insertion port 31B, for example, a pin shape. The insertion member 522 is approximately contained within the insertion port 31B. Thus, during the insertion of the insertion member 522 into the insertion port 31B, the support member 30 and the connecting member 52 are securely connected. Alternatively, an insertion port may be provided on the connecting member 52, and an insertion member inserted into this insertion port may be provided on the support member 30.

[0044] The connecting member 52 includes: a main body 521 supported by the guide 51 so as to move along the guide 51; and a lifting mechanism 523 supported by the main body 521 and moving together with the main body 521. An insertion member 522 is fixed to the lower end of the lifting mechanism 523, and the lifting mechanism 523 causes the insertion member 522 to move up and down. The lifting mechanism 523 is implemented, for example, by an actuator such as a cylinder. The control unit 1 drives the lifting mechanism 523 to move the insertion member 522 in the vertical direction, thereby inserting or removing the insertion member 522 relative to the insertion port 31B. That is, the connecting member 52 switches between a connected state connected to the support member 30 and a disconnected state, where the connection with the support member 30 is released, by the lifting and lowering of the insertion member 522 relative to the insertion port 31B. The connected state is the state where the insertion member 522 is inserted into the insertion port 31B. The disconnected state is the state where the insertion member 522 is not inserted into the insertion port 31B. In addition, if the connecting member 52 is provided with an insertion port, the insertion port can be raised or lowered relative to the insertion member provided on the support member 30.

[0045] The control unit 1 drives the actuator 53 to reciprocate the connecting member 52 along the guide 51 between the vicinity of the first position P1 and the vicinity of the second position P2. Additionally, the control unit 1 drives the lifting mechanism 523 to attach and detach the connecting member 52 relative to the supporting member 30. By combining the aforementioned actions of the actuator 53 and the lifting mechanism 523, the control unit 1 causes the supporting member 30 connected to the connecting member 52 to reciprocate between the first position P1 and the second position P2.

[0046] The ejection mechanism 60 is a mechanism for ejecting workpieces W1 from the feed box 7. Multiple workpieces W1 are stored in the feed box 7 at vertical intervals. When the supporting member 30 is positioned in the first position P1, the ejection mechanism 60 ejects the workpieces W1 one by one from the feed box 7, placing them on the mounting surface C1 of the supporting member 30.

[0047] like Figures 2A to 2I As shown, the ejection mechanism 60 has a guide 61, a push rod 62 that moves along the guide 61, and an actuator 63 (drive source) that drives the push rod 62 to move along the guide 61. The guide 61 is disposed on the opposite side of the alignment mechanism 4 across the feed box 7. The actuator 63 is implemented, for example, by a servo motor. In this case, the guide 61 is implemented, for example, as a ball screw connected to the output shaft of the servo motor.

[0048] In this embodiment, the push rod 62 is a generally rectangular plate-shaped component, but is not limited thereto. A cutout portion 62A is appropriately formed on the push rod 62. The push rod 62 achieves weight reduction through the cutout portion 62A. The cutout portion 62A can be a through hole or a bottomed opening.

[0049] The push rod 62 is supported by the guide 61 to move along the guide 61. The control unit 1 drives the actuator 63 to move the push rod 62 along the guide 61 to the third position P3 (see reference). Figure 2A (etc.) and the fourth position P4 (refer to) Figure 2C The feed box 7 moves back and forth between the feed rod and the other position. The third position P3 is located outside the feed box 7. The fourth position P4 is partially located inside the feed box 7. When the support member 30 is positioned in the first position P1, the push rod 62 moves along the guide 61 from the third position P3 to the fourth position P4. Accompanying this, a piece of workpiece W1 inside the feed box 7 is pushed outward by the push rod 62 and placed on the mounting surface C1 of the support member 30 positioned in the first position P1 (see reference). Figure 2C (etc.). The feed box 7 is height-adjustable, and the workpiece W1 taken out from the feed box 7 is adjusted to the same height position as the push rod 62. Whenever a workpiece W1 is taken out by the ejection mechanism 60, the control unit 1 moves the feed box 7 in the vertical direction so that the next workpiece W1 taken out is at the same height position as the push rod 62.

[0050] A guide mechanism 80 is provided near the workpiece W1 outlet of the feed box 7. Figure 5 yes Figure 2A A VV-line sectional view. (See example...) Figure 2A and Figure 5 As shown, the guide mechanism 80 has a support plate 81 that is generally rectangular in top view and a pair of sidewalls 82, 82 respectively disposed at both ends of the support plate 81 in the front-rear direction. The sidewalls 82, 82 protrude upward from the upper surface of the support plate 81. Each sidewall 82 has a step at its upper end, with a first step portion 821 further inward and a second step portion 822 further outward. The height of the second step portion 822 is higher than that of the first step portion 821. When the bearing member 30 is disposed in the first position P1, the pair of first step portions 821, 821 are respectively disposed on the approximate extension lines of the protrusions 33, 34 of the bearing member 30. In the same state, the pair of second step portions 822, 822 are respectively disposed on the approximate extension lines of the sidewalls 43, 44 included in the alignment mechanism 4.

[0051] With the supporting component 30 positioned at the first position P1, the upper surfaces of the first stepped portions 821 and 821 are aligned at their heights with the upper surfaces of the protrusions 33 and 34. The guiding mechanism 80 forms a virtual surface, namely the mounting surface C2, which includes the upper surfaces of the first stepped portions 821 and 821 (see reference). Figure 5 The workpiece W1, ejected from the outlet of the feed box 7, is first received on the upper surface (i.e., the mounting surface C2) of a pair of first stepped portions 821, 821. It slides along the upper surface of the pair of first stepped portions 821, 821 while passing through the guide mechanism 80, and is then received on the upper surface (i.e., the mounting surface C1) of the protrusions 33, 34. Figure 5 In the diagram, the workpiece W1 on the first step portions 821, 821 is indicated by a dashed line as a reference. Similar to the mounting surface C1, the mounting surface C2 also has a recess 83 to reduce the contact area between the guide mechanism 80 and the workpiece W1 when it is mounted. That is, the workpiece W1 does not contact the guide mechanism 80 except for the upper surface of the first step portions 821, 821. The recess 83 is formed between the first step portions 821, 821, and is a space recessed downwards from the upper surface of the first step portions 821, 821. Therefore, due to the recess 83, the contact area between the workpiece W1 and the object (guide mechanism 80) is reduced, lowering the risk of damage or deformation to the workpiece W1 due to friction with the object (guide mechanism 80).

[0052] The second step portions 822 and 822 protrude upwards from the outer side of the first step portions 821 and 821. Therefore, the workpiece W1 is accurately aligned along the width direction (front-back direction) on the first step portions 821 and 821, preventing it from falling off. Furthermore, the spacing between the second step portions 822 and 822 is slightly wider than the spacing between the side walls 43 and 44 included in the alignment mechanism 4 when they are closest to each other. Additionally, as... Figures 2A to 2I As shown, each of the second step portions 822 has an inclined surface 822A near the outlet of the feed box 7 when viewed from above. Therefore, the spacing between the second step portions 822, 822 is widest at the position closest to the outlet of the feed box 7, gradually narrows as it moves away from the outlet of the feed box 7, and becomes a constant width near the alignment mechanism 4. As described above, even if the workpiece W1 experiences a positional shift in the width direction (front-back direction) on the first step portions 821, 821 when it is pushed out of the feed box 7, it will be gradually pushed towards the center in the width direction during its passage between the second step portions 822, 822. As a result, when the workpiece W1 reaches the support member 30 positioned at the first position P1, it will not experience a large positional shift in the width direction, but will be received by the support member 30 in a substantially accurate position.

[0053] <3. Manufacturing Method of Resin Molded Articles> Next, refer to Figures 2A to 2I The process of manufacturing resin molded articles using the resin molding apparatus 100 is described below. When the operator places the feed box 7 containing multiple workpieces W1 in the feed module M1 and performs the prescribed operation via the touch panel 9, the resin molding apparatus 100 begins manufacturing resin molded articles (workpieces W2).

[0054] First, the control unit 1 sets the rotating disk 40 to... Figure 2A The position is shown. Thus, a support member 30 (more specifically, the front side) mounted on the rotating disk 40 is positioned at the second position P2. Furthermore, the control unit 1 drives the actuator 53 to position the connecting member 52 near the second position P2, thereby positioning the insertion part 522 of the connecting member 52 directly above the insertion port 31B of the support member 30 on the front side. In this state, the control unit 1 drives the lifting mechanism 523 to lower the insertion part 522. As a result, the insertion part 522 is inserted into the insertion port 31B, and the support member 30 on the front side is connected to the connecting member 52.

[0055] Next, the control unit 1 drives the actuator 53, causing the connecting member 52 to move along the guide 51 from near the second position P2 to near the first position P1 (see reference). Figure 2BAs a result, the support member 30 connected to the connecting member 52 moves from the second position P2 to the first position P1. Next, the control unit 1 separates the side walls 43 and 44 of the support mechanism 41 that supports the support member 30 positioned in the first position P1. In this state, the control unit 1 drives the actuator 63, causing the push rod 62 to move along the guide member 61... Figure 2C The fourth position P4 is shown. Here, the workpiece W1 is pushed out of the feed box 7 by the push rod 62, and placed on the mounting surface C1 of the bearing member 30 located at the first position P1 (see reference 80). Figure 2C That is, the supporting member 30 receives the workpiece W1 from the feed box 7 to the mounting surface C1 at the first position P1. When the workpiece W1 is placed on the mounting surface C1, the control unit 1 brings the side walls 43 and 44 of the support mechanism 41 closer together, thereby aligning the workpiece W1 along the width direction on the mounting surface C1. Alternatively, the control unit 1 may not perform the alignment of the workpiece W1 along the width direction at the first position P1, but after the workpiece W1 has moved to the second position P2.

[0056] Next, the control unit 1 drives the actuator 53, causing the connecting member 52 to move along the guide 51 from near the first position P1 to near the second position P2. As a result, the supporting member 30, with the workpiece W1 placed on the mounting surface C1, moves from the first position P1 to the second position P2 (see reference). Figure 2D As a result, the supporting component 30 is positioned at the second position P2 along with the workpiece W1 on the alignment mechanism 4. Additionally, the control unit 1 drives the actuator 63, causing the push rod 62 to retract along the guide member 61 to... Figure 2D The third position P3 is shown. Then, the control unit 1 raises and lowers the feed box 7, setting the next ejected workpiece W1 at the same height as the push rod 62.

[0057] Next, the control unit 1 drives the lifting mechanism 523 to raise the insertion member 522 of the connecting member 52, thereby positioning the insertion member 522 directly above the insertion port 31B. The insertion member 522 is then pulled out of the insertion port 31B, releasing the connection between the support member 30 and the connecting member 52. In this state, the control unit 1 rotates the rotating disk 40 180°, thereby exchanging the positions of the two support mechanisms 41, and consequently, the positions of the two support members 30 (see reference). Figure 2E As a result, the workpiece W1 is held on the back side of the support member 30, while the front side of the support member 30 becomes empty.

[0058] At this stage, the support member 30 on the front side is positioned at the second position P2, and the insertion member 522 of the connecting member 52 is positioned directly above the insertion port 31B of the support member 30. From here, the same actions as when setting the first workpiece W1 are repeated.

[0059] That is, the control unit 1 drives the lifting mechanism 523 to lower the insertion member 522, thereby connecting the front-side support member 30 and the connecting member 52. Next, the control unit 1 drives the actuator 53 to move the front-side support member 30 from the second position P2 to the first position P1 (see reference). Figure 2F ).

[0060] Next, the control unit 1 drives the actuator 63, and the push rod 62 pushes the workpiece W1 from the feed box 7 onto the mounting surface C1 of the carrier component 30 (see reference). Figure 2G In addition, similar to the first workpiece W1, before and after the second workpiece W1 is pushed out of the feed box 7, the side walls 43 and 44 of the front support mechanism 41 are also brought closer or separated to align the workpiece W1.

[0061] Next, the control unit 1 drives the actuator 53 to move the front-side support member 30 from the first position P1 to the second position P2 (see reference). Figure 2H Therefore, the second supporting component 30 is also positioned at the second position P2 along with the second workpiece W1 in the alignment mechanism 4. Additionally, the control unit 1 retracts the push rod 62 to the third position P3. Furthermore, the control unit 1 drives the lifting mechanism 523 to pull out the insertion component 522 from the insertion port 31B, thereby disconnecting the supporting component 30 from the connecting component 52.

[0062] At this stage, two workpieces W1 are placed on the rotary table 40. Next, the control unit 1 rotates the rotary table 40 to a position suitable for pickup by the loader 5 (see reference). Figure 2I ), and arrange the two workpieces W1 in an array. Figure 2I In this example, the rotary table 40 rotates 90°. Additionally, the control unit 1 moves the rotary table 40 to the junction position on the loader 5 side (rear side) (see reference). Figure 2I Simultaneously, the loader 5 is moved directly above the handover position. When the workpiece W1 on the rotary table 40 is aligned vertically with the loader 5, the workpiece W1 is picked up from the rotary table 40 by the picking mechanism 5a and transported to the molding die 20. Additionally, the resin material T is also transported to the molding die 20 by the picking mechanism 5a. Only the workpiece W1 is picked up from the rotary table 40; the supporting component 30 remains on the rotary table 40. When the workpiece W1 is picked up from the rotary table 40, the control unit 1 repositions the rotary table 40, the supporting component 30, and the connecting component 52 back to their original positions. Figure 2A Repeat at the position shown. Figures 2B to 2I The actions shown include the action of conveying the workpiece W1 and the resin material to the molding die 20.

[0063] Whenever workpiece W1 and resin material T are conveyed to molding die 20, control unit 1 controls molding mechanism 2 to perform resin molding on workpiece W1 within molding die 20, processing it into workpiece W2. The resulting resin-molded product (workpiece W2) is removed from molding die 20 by unloading machine 6, and after unwanted resin such as sprue and runner is removed by removal unit (not shown), it is conveyed to discharge box 8. As described above, the manufacturing process of the resin-molded product is complete.

[0064] <4. Characteristics> In the above embodiment, the workpiece W1 exiting from the feed box 7 is placed on the carrying member 30. Then, the carrying member 30, with the workpiece W1 placed on it, is moved by the moving mechanism 50 to a predetermined position (second position P2) of the aligning mechanism 4. That is, the workpiece W1 itself is not directly pulled or dragged, but the carrying member 30 carrying the workpiece W1 is transported. As a result, even for workpiece W1 with low rigidity, the risk of deformation such as bending or twisting or falling off the transport path during transport can be reduced. Therefore, workpiece W1 can be transported at high speed between the feed box 7 and the predetermined position (second position P2) of the aligning mechanism 4. As a result, the production speed of resin molded products (workpiece W2) can be increased, and the production quantity of resin molded products per unit hour (UPH) can be increased.

[0065] The above describes one embodiment of the present invention, but the present invention is not limited to the above embodiment, and various modifications can be made without departing from its spirit.

[0066] <5. Postscript> <Technology 1> (constitute) A resin molding apparatus, comprising: Storage department, for storing workpieces; An aligning mechanism for aligning the workpieces; The conveying mechanism moves the workpiece from the receiving section to the aligning mechanism; and A molding die is used to resin mold the workpieces transported from the alignment mechanism. The conveying mechanism includes: a supporting member having a mounting surface for placing the workpiece; and a moving mechanism for moving the supporting member from a first position to a second position while the workpiece is mounted on the mounting surface. The supporting component receives the workpiece from the receiving part to the placing surface at the first position, and is placed on the aligning mechanism together with the workpiece at the second position.

[0067] (Effects, etc.) In this resin molding apparatus, workpieces exiting the receiving section are placed on a carrying member. Then, the carrying member, with the workpieces on it, is moved by a moving mechanism to a predetermined position (second position) on the aligning mechanism. That is, the workpieces themselves are not directly pulled or dragged; rather, the carrying member holding the workpieces is conveyed. As a result, even for workpieces with low rigidity, the risk of deformation such as deflection or twisting during conveying, or the workpiece falling off the conveying path, is reduced. Therefore, workpieces can be conveyed at high speed between the receiving section and the predetermined position on the aligning mechanism. Consequently, the production quantity of resin molded products per unit time can be increased.

[0068] <Technology 2> (constitute) According to the resin molding apparatus of technology 1, wherein... The mobile mechanism includes: The guide extends from near the first position to near the second position; The connecting component is detachably connected to the supporting component and moves along the guide; and A driving source drives the connecting component to move along the guide.

[0069] (Effects, etc.) This resin molding apparatus allows for the transport of the supporting components with a simple structure. Therefore, it further reduces the time required for workpiece transport and increases the production quantity of resin molded products per unit time.

[0070] <Technology 3> (constitute) According to the resin molding apparatus of technology 2, wherein... One of the supporting component and the connecting component has an insertion port. The other of the supporting member and the connecting member has an insertion member that is inserted into the insertion port in a manner that connects the supporting member and the connecting member.

[0071] (Effects, etc.) In this resin molding apparatus, the connecting parts can be assembled and disassembled relative to the supporting parts with a simple structure. Therefore, the time required for workpiece transport can be further reduced, and the production quantity of resin molded products per unit time can be further increased.

[0072] <Technology 4> (constitute) According to the resin molding apparatus of technology 3, wherein... The connecting component moves up and down relative to the insertion port via the insertion component, switching between a connected state where the insertion component is inserted into the insertion port and connected to the support component, and a disconnected state where the insertion component is not inserted into the insertion port and disconnected from the support component.

[0073] (Effects, etc.) In this resin molding apparatus, the connecting parts can be assembled and disassembled relative to the supporting parts with a simpler structure. Therefore, the time required for workpiece transport can be further reduced, and the production quantity of resin molded products per unit time can be further increased.

[0074] <Technology 5> (constitute) The resin molding apparatus according to any one of techniques 1 to 4, wherein... The alignment mechanism is capable of rotating in a horizontal plane and can carry two of the aforementioned support components.

[0075] (Effects, etc.) This resin molding apparatus can simultaneously align two workpieces. Therefore, the production quantity of resin molded products per unit time can be further increased.

[0076] <Technology 6> (constitute) The resin molding apparatus according to any one of techniques 1 to 5, wherein... A recess is provided on the mounting surface, which is used to reduce the contact area between the supporting component and the workpiece when the workpiece is mounted.

[0077] (Effects, etc.) In this resin molding apparatus, the contact area between the workpiece and the supporting component is reduced, thereby decreasing the risk of damage or deformation to the workpiece due to friction with the supporting component.

[0078] <Technology 7> (constitute) The resin molding apparatus according to any one of techniques 1 to 6, wherein, The conveying mechanism further includes a pushing mechanism, which pushes the workpiece out of the receiving part and places it on the placement surface when the carrying component is positioned in the first position.

[0079] (Effects, etc.) In this resin molding apparatus, workpieces can be placed on the mounting surface of the supporting component with a simple structure. Therefore, the time required for workpiece transport can be further reduced, and the production quantity of resin molded products per unit time can be further increased.

[0080] <Technology 8> (constitute) A method for manufacturing a resin molded article, comprising: Using any one of the resin molding apparatuses described in techniques 1 to 7, the workpiece is resin molded in the molding die to manufacture a resin molded article.

[0081] (Effects, etc.) In this method for manufacturing resin molded articles, the production quantity of resin molded articles per unit time can be increased.

Claims

1. A resin molding apparatus, comprising: Storage department, for storing workpieces; An aligning mechanism for aligning the workpieces; A conveying mechanism moves the workpiece from the storage section to the aligning mechanism; and A molding die is used to resin mold the workpieces transported from the alignment mechanism. The conveying mechanism includes: The supporting component has a mounting surface for placing the workpiece; And a moving mechanism, which moves the supporting member from a first position to a second position when the workpiece is placed on the mounting surface. The supporting component receives the workpiece from the receiving part to the placing surface at the first position, and is placed on the aligning mechanism together with the workpiece at the second position.

2. The resin molding apparatus according to claim 1, wherein, The moving mechanism includes: A guide extends from near the first position to near the second position; The connecting component is detachably connected to the supporting component and moves along the guide; and A driving source drives the connecting component to move along the guide.

3. The resin molding apparatus according to claim 2, wherein, One of the supporting component and the connecting component has an insertion port. The other of the supporting member and the connecting member has an insertion member that is inserted into the insertion port in a manner that connects the supporting member and the connecting member.

4. The resin molding apparatus according to claim 3, wherein, The connecting component moves up and down relative to the insertion port via the insertion component, switching between a connected state where the insertion component is inserted into the insertion port and connected to the support component, and a disconnected state where the insertion component is not inserted into the insertion port and disconnected from the support component.

5. The resin molding apparatus according to any one of claims 1 to 4, wherein, The alignment mechanism is capable of rotating in a horizontal plane and can carry two of the aforementioned support components.

6. The resin molding apparatus according to any one of claims 1 to 5, wherein, A recess is provided on the mounting surface, which is used to reduce the contact area between the supporting component and the workpiece when the workpiece is mounted.

7. The resin molding apparatus according to any one of claims 1 to 6, wherein, The conveying mechanism further includes a pushing mechanism, which pushes the workpiece out of the receiving part and places it on the placement surface when the carrying component is positioned in the first position.

8. A method for manufacturing a resin molded article, comprising: Using the resin molding apparatus according to any one of claims 1 to 7, the workpiece is resin molded in the molding die to manufacture a resin molded article.

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