Forming device, forming process and formed products

Abstract

Device for producing shaped products (70) using a film-like insertion material (80), the device comprising: a transfer device (87) for transferring the insertion material (80) into a mold (40); and an injection device (20) for injecting a molding material into the mold, wherein the injection device (20) is set up to inject the molding material into the mold when the insertion material (80) has been deformed inside the mold (40), and the transfer device (87) is set up to deform the insertion material (80) within the mold (40) such that one end of the insertion material overlaps with a part of the insertion material.

Description

REFERENCE TO RELATED REGISTRATIONS

[0001] The present invention claims the advantages of: Japanese patent application no. 2014-095336, filed on May 2, 2014; Japanese patent application no. 2014-095355, filed on May 2, 2014; Japanese patent application no. 2014-095365, filed on May 2, 2014; Japanese patent application no. 2015-018612, filed on February 2, 2015; Japanese patent application no. 2015-018623, filed on February 2, 2015; and Japanese patent application no. 2015-018631, filed on February 2, 2015, the entire contents of which are incorporated herein by reference. BACKGROUND OF THE INVENTION 1. Technical Field

[0002] The present invention relates to a forming device, a forming process and formed products. 2. State of the art

[0003] In recent years, various efforts have been actively undertaken to reduce the weight of vehicle bodies in order to increase the fuel efficiency of automobiles or the range of hybrid or electric vehicles. One well-known method for saving weight is the process of replacing the metal components of automobiles with carbon fiber reinforced plastic (CFRP) or glass fiber reinforced plastic (GFRP).

[0004] A well-known technique for manufacturing CFRP or GFRP molded products involves forming an insertion material (textile film), such as film-like carbon fibers and glass fibers, using a press or similar device, and then inserting the formed insertion material into a mold and injection molding to integrally form the insertion material with the resin material (JP-2013-202825-A and JP-2012-179773-A).

[0005] In principle, to facilitate the processing of textile films such as carbon fiber or glass fiber films incorporated into CFRP or GFRP, these are often cut into the required shapes before the molded products are manufactured. The edges of the cut textile films can fray, causing the carbon fiber threads to separate. These frayed fiber threads can sometimes become trapped in the mold, causing problems such as mold damage. To address this problem, JP-2010-194863-A was disclosed. Further relevant prior art can be found in publications DE 692 15 614 T2, US 5 558 883 A, and DE 10 2009 052 123 A1. PRESENTATION OF THE INVENTION

[0006] However, JP-2013-202825-A and JP-2012-1779773-A only disclose a method for simply placing an insertion material on the surface of a mold cavity. This means that the method does not involve placing a film-like insertion material within the mold by deformation. Therefore, conventional techniques for placing a film-like insertion material at a desired position depending on the mold present challenges.

[0007] Furthermore, in JP-2010-194863-A, a molded plastic or resin product is manufactured from time to time, the edges of which are covered only by plastic or resin material and are formed from a cut textile film. Consequently, because the textile film, which serves as the infill material (reinforcing material), is not incorporated into the edges of the resin-molded product at the time of manufacture, the strength of the molded resin product at the edges may be lower compared to that in other sections (central sections). Along with this reduction, problems such as fluctuating product quality arise.

[0008] The present invention was made taking into consideration the above, and an objective of the invention is to provide a forming device, a forming method, and formed products in which a film-like insertion material can be deformed and easily placed in a predetermined position at a time when insertion material is placed in a mold.

[0009] The problem is solved by the subject matter of claims 1, 2 and 7.

[0010] In one aspect of the invention, the invention is a device for producing shaped products using a film-like insertion material, wherein the device comprises: a transfer device for transferring the insertion material into a mold; and an injection device for injecting a forming material into the mold, wherein the injection device injects the forming material into the mold, deforming the insertion material in the mold.

[0011] Another aspect of the invention is a method for producing a shaped product using a film-like insertion material, wherein the method includes: a transfer step for transferring the insertion material into a mold using a transfer device; a placement step for placing the insertion material in the mold by deforming the insertion material in the mold; and a forming step for injecting a forming material into the mold, thereby producing the shaped product comprising the insertion material.

[0012] Another aspect of the invention is a method wherein the placement step includes a deformation step to overlap one end of the insertion material with a part of the insertion material using the transfer device.

[0013] Another aspect of the invention is a method wherein, by injecting the molding material into the mold during the molding step, the end of the insertion material and the part of the insertion material that overlaps with each other are bonded together.

[0014] Another aspect of the invention is a method wherein the insertion material comprises one end and another end and wherein one end of the insertion material overlaps the other end of the insertion material during the deformation step.

[0015] Another aspect of the invention is a method wherein, during the deformation step, the end of the insertion material is folded onto itself, thereby layering or laminating the end.

[0016] Another aspect of the invention is a method wherein the forming material flows into the area where the end of the insertion material and the part of the insertion material overlap.

[0017] Another aspect of the invention is a shaped product that is produced by one of the methods described above.

[0018] Another aspect of the invention is a shaped product comprising: a material section; and a reinforcing material section formed integrally with the material section, wherein the reinforcing material is bent and one end of the reinforcing material overlaps a part of the reinforcing material and wherein the end of the reinforcing material and the part of the reinforcing material that overlaps are bonded together.

[0019] According to the present invention, the insertion material is placed within the mold by deformation, and a shaped product containing the insertion material is produced by injecting a forming material into the mold in this state. Thus, after a film-like insertion material is placed in the mold, it can be deformed and easily positioned in a predetermined location. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 is a front cross-sectional view showing part of an injection molding machine according to an embodiment of the invention; Fig. 2 is a cross-section of a mold of an injection molding machine according to an embodiment of the invention (a cross-section extending along line II-II of Fig. 1 was done); Fig. Figure 3 is a front view of a shaped product, according to an embodiment of the invention; Fig. Figure 4 is an explanatory diagram of an injection molding cycle; Fig. Drawings 5A to 5G depict a method for producing shaped products according to the embodiment of the invention; Fig. Figure 6 is a front view of a molded product according to a modification example; and Fig. 7A and Fig. 7B are drawings that illustrate a process for manufacturing shaped products according to the modification example. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0020] Embodiments of the present invention are described below with reference to Fig. 1 to 7 described. Fig. Figures 1 to 7 are drawings illustrating embodiments of the invention. In each figure, identical numbers denote identical elements, and detailed descriptions are omitted in parts of the figures. Construction of the injection molding machine

[0021] First, the structure of an injection molding machine (device for producing shaped products or molding device) is described in relation to Fig. 1 and Fig. 2 described. Fig. Figure 1 is a front cross-sectional view of an injection molding machine according to the present embodiment, while Fig. 2 is a cross-section that represents the internal structure of a shape.

[0022] As in Fig. As shown in Figure 1, the injection molding machine 10 includes the following components: a base 11; an injection device 20 provided on the base 11; a clamping device 30 provided on the base 11; and a control 60 for controlling the entire injection molding machine 10.

[0023] Among these components, the injection device 20 includes an injection mechanism 21 and a cylinder 22 extending horizontally from the injection mechanism 21. A screw 23 is provided inside the cylinder 22. A nozzle 24 is provided at the distal end of the cylinder 22. The injection device 20 is movably positioned in the direction in which it approaches or moves away from the clamping device 30 at the base 11 (X-direction).

[0024] A form 40, which includes a fixed form 41 and a movable form 42, is fixed to the clamping device 30.

[0025] This clamping device 30 includes the following components: a pressure plate 31 which is fixed to the base 11; a fixed plate 32 which supports the fixed form 41 and is fixed to the base 11; and a movable support plate 33 which is provided opposite the fixed plate 32, which supports the movable form 42 and is movably arranged with respect to the fixed plate 32.

[0026] Furthermore, the fixed support plate 32 and the pressure plate 31 are connected by several (for example, four) spindles 34 at a predetermined distance between them. The movable support plate 33 moves along the spindles 34 in a direction in which it approaches or moves away from the fixed support plate 32.

[0027] As a result of the movable support plate 33 moving in the direction in which it approaches the fixed support plate 32 (mold closing direction), the mold closing of the fixed mold 41 and the fixed mold 42 is carried out. Additionally, if the movable support plate 33 moves in a direction in which it moves away from the fixed support plate 32 (mold opening direction), the mold opening of the fixed mold 41 and the movable mold 42 is carried out.

[0028] An assembly device 87, such as an unloading machine or a robot for transferring an insertion material 80, which will be described later, is provided near the form 40.

[0029] The construction of Form 40 will be described next with reference to Fig. 1 and Fig. 2 described.

[0030] As explained above, the mold 40 comprises the fixed mold 41 and the movable mold 42. The fixed mold 41 includes a gate 43 into which a resin material (molding material or molding substance) introduced by the injection device 20 flows. The movable mold 42 is movable in the direction in which it approaches or moves away from the fixed mold 41 (X-direction) due to the movable support plate 33.

[0031] The mold 40 includes a nest 44 into which the resin material is introduced and a collecting plate (collection element) 45, which is capable of moving back and forth within the nest 44. The nest 44 is formed between the fixed mold 41 and the movable mold 42 and has a shape corresponding to a molded product 70, which will be described later.

[0032] The collecting plate 45 is designed to enter and exit the movable form 42 by means of a drive mechanism (not shown). The collecting plate 45, which is controlled by the control unit 60, is designed to maintain the collecting position within the nest 44 (see Fig. 1) to assume or to assume the retracted position in which the collecting plate 45 is drawn into the movable mold 42. More precisely, as described later, the control unit 60 controls the injection device 20 at a point during the injection filling (injection) of the resin material through the injection device 20, controls the flow of the resin material into the cavity 44 using the collecting plate 45 in the initial phase of the injection filling (injection), and then controls the collecting plate 45 so that the collecting plate 45 is drawn into the side of the movable mold 42.

[0033] When the collecting plate 45 is in the collecting position, it passes through the cavity 44 and moves upwards to the position where it comes into contact with the fixed mold 41. The gate 43 is located on one side (top side) of the collecting plate 45. Consequently, the collecting plate 45 regulates the flow of resin material from the gate 43 into the cavity 44. More precisely, the resin material is only able to flow towards one side (top side) of the collecting plate 45 and will not flow directly into the other side (bottom side) of the collecting plate 45 from the gate 43.

[0034] On the other hand, when the collecting plate 45 is in a retracted position, it is completely retracted into the movable mold 42. At this point, the resin material flows from the gate 43 within the nest 44 without being blocked by the collecting plate. More precisely, the resin material can flow not only towards one side (top) of the collecting plate 45, but also towards the other side (bottom). It should be noted that the collecting plate 45 can alternatively enter and exit the fixed mold 41.

[0035] While in the present embodiment, as in Fig. Figure 2 shows that the collection plate 45 is designed to have a rectangular plate shape in a vertical cross-section (the cross-section parallel to the YZ plane). However, the shape of the collection plate 45 is not limited to this. For example, the collection plate 45 can instead be designed in a triangular or elliptical shape in the vertical cross-section (the cross-section parallel to the YZ plane).

[0036] Within the nest 44, a pair of cylindrical shaft elements 46 are positioned so that they extend between the fixed mold 41 and the movable mold 42. These shaft elements 46 are each connected to the fixed mold 41. As described later, when the resin material is injected into the mold 40, an insertion material 80 is wrapped around the pair of shaft elements 46. Note that the catch plate 45 extends in a horizontal direction (Y-direction) from one shaft element 46 to the other. Additionally, the fixed mold 41 includes a projection 47 located below the shaft element 46. This projection 47 is used to position an insertion material 80, with one end 81 and the other end 82 of the insertion material 80 overlapping at the time the resin material is injected into the mold 40, as described later.

[0037] As in Fig. As shown in Figure 2, the nest 44 comprises: a resin influence chamber (molding material influence chamber) 51, in which the gate is provided and into which the resin material flows; a separation chamber 52, which is suitable for being connected to the downstream side of the resin influence chamber 51 and is provided at the position where the resin material separates; and a pair of flow paths 53a and 53b, into each of which resin material separating from the separation chamber 52 flows. Furthermore, the pair of flow paths 53a and 53b is suitable for being connected to each other at a crossing section 54, which is located downstream of the separation chamber 52.

[0038] The separation space 52, the pair of flow paths 53a and 53b, and the intersection section 54 together form a ring shape, and each of the shaft elements 46 is surrounded by this ring. It should be noted that, as in Fig. 2 shown, the width of the projection 47 (length in Y direction) is equal to the width of the resin influence space 51 or less than a width of the resin influence space 51.

[0039] In this case, the nest 44 includes a pair of separation spaces 52 located on both sides of the horizontal direction of the resin influence space 51, although the nest 44 is not limited to this. The number of separation spaces 52 can also be greater than three.

[0040] The controller 60 can, for example, be a computer comprising a CPU, ROM, RAM, and an external storage device. Based on various information inputs, this controller 60 operates the injection unit 20, the clamping unit 30, the collection plate 45, and the assembly unit 87. Information inputs to the controller 60 include, for example, control commands or molding information inputs from the operator or an external device. Since this is the case, the controller (control unit) 60 is designed to control the entire injection molding machine 10. However, in the present embodiment, the controller 60 can be any device as long as it is capable of controlling at least the injection unit 20 and the collection plate 45. Construction of a molded product

[0041] The structure of a molded product manufactured by the injection molding machine 10 described above is described below with reference to Fig. 3 described. Fig. Figure 3 is a front view showing the formed product 70 according to the present embodiment.

[0042] As in Fig. As shown in Figure 3, the molded product 70 is a material in which, for example, a fiber-reinforced resin such as carbon fiber reinforced plastic (CFRP) or glass fiber reinforced plastic (GFRP) is used. The molded product 70 has: a material section 71 (resin section) which includes a resin (material); and an insertion material (prepreg, insertion element, reinforcing element, or reinforcing material) 80 which is integrally formed with the material section 71.

[0043] Among these, material section 71 includes a shaped main product body section 73 and a pair of diverging sections 74 provided on both sides of the shaped main product body section 73. A pair of branch sections 75a and 75b, diverging from each of the diverging sections 74, are connected to each other at the connecting section 76.

[0044] The molded main product body section 73, located at the central section of the molded product 70, corresponds to the resin influence chamber 51 of mold 40 described above. Additionally, the molded main product body section 73 includes a gate-corresponding section 72, which corresponds to the gate 43 of mold 40. The diverging sections 74, the branch sections 75a and 75b, and the connecting section 76 each correspond to the diverging chambers 42, the flow paths 53a and 53b, and the crossing section 44 in mold 40.

[0045] The branching sections 74, the pair of branching sections 75a and 75b, and the connecting section 86 together form a ring shape, and a circular through-hole 77 is formed in each of the rings. The through-hole 77 has a shape corresponding to that of a shaft element 46 of form 40.

[0046] Due to the spreading of the resin material during injection molding, a weld line W is formed on the molded main body section 73 of the molded product 70. This weld line W is located closer to the area corresponding to the catch plate 45 of the mold 40 described above. Specifically, the weld line W extends along the direction in which the resin material flows within the resin influence area 41 of the cavity 44, or in a longitudinal direction (Y-direction) of the molded main body section 73. Furthermore, the weld line W extends along a lateral direction (Z-direction) of the molded main body section 73 to the position opposite the gate corresponding section 72 with respect to the catch plate 54 surrounding the molded main body section 73.

[0047] In contrast, no weld seam W is formed on the pair of branch sections 75a and 75b and on the connecting section 76. Consequently, the weld seam W can be placed away from branch sections 75a and 75b and the connecting section 76b, which tend to have lower strength, thereby improving the strength of branch sections 75a and 75b and the connecting section 76.

[0048] The insertion material (insertion element, reinforcement material, or reinforcing element) 80 is formed from a film-like material and is designed to surround the outer section of the material section 71 while bent. Additionally, the insertion material 80 includes one end 81 and the other end 82 and is integrally formed with the material section 71, with one end 81 overlapping the other end 82. That is, the length of the insertion material 80 is longer than the length of the outer section of the formed product 70.

[0049] The area where one end 81 and the other end 82 of the insertion material 80 overlap is, for example, near the formed main product body section 73; in the present embodiment, it is essentially at the central section of the longitudinal direction (Y-direction) of the formed main product body section 73. As above, the adhesion of the ends 81 and 82 of the insertion material 80 prevents a reduction in the local strength of the formed product 70. Furthermore, the overlapping of the ends 81 and 82 of the insertion material 80 prevents a reduction in the strength of the joint of the insertion material 80. Since the weld line W is also provided in the area where the ends 81 and 82 of the insertion material overlap, the strength around the weld line W can be increased.

[0050] It should be noted that the area overlapped by one end 81 of the insertion material 80 need only be a part of the insertion material 80 and does not necessarily have to be at the other end 82. For example, it is instead possible for one end 81 to extend in the (-Y) direction in Fig. 3 to extend in order to overlap one end 81 with the insertion material 80 near the through-hole 77. Alternatively, regardless of whether one end 81 or the other end 82 is overlapping, it is also possible to fold one end 81 (or the other end 82) to increase the strength of one end 81 (or the other end 82).

[0051] It should be noted that the forming material 71-M (synthetic resin or resin material) that forms material section 71 can be an epoxy-based resin, a polyamide-based resin, or a phenol-based resin. Furthermore, an insertion material 80 can, for example, be a film formed by immersing a continuous fiber, such as a carbon fiber or glass fiber, or a long fiber, in resin.

[0052] The molded product 70 is capable of achieving a mechanical strength greater than that of an injection-molded product made from synthetic resin alone, due to the introduction of the filler material 80 into the molded product 70. Such a molded product 70 can be used, for example, as an automotive component, aircraft component, architectural component, or industrial machinery component. Methods for producing shaped products

[0053] A method for producing a shaped product, in particular the method for producing the shaped product 70, which is described in Fig. As shown in 3, the injection molding machine 10, which is located in the Fig. 1 and Fig. As shown in section 2, it is explained.

[0054] First, the basic injection molding process is briefly described. As in Fig. As shown in Figure 4, the molded product 70 is produced using the injection molding machine 10 of the present embodiment by performing an injection molding cycle S100. More precisely, the injection molding cycle S100 includes a mold clamping step S101, an injection step S102, a dwell and cooling step S103, a mold opening step S104, and a product discharge step S105, wherein repeating these steps in this sequence produces a large number of molded products 70.

[0055] The process for producing shaped products 70 is further described with reference to the Fig. 5A to 5G described. Fig. Drawings 5A to 5G are illustrations depicting a method for producing shaped products according to the present embodiment; among these are Fig. 5b to 5G drawings, which are essentially Fig. 2 correspond. It should be noted that the injection molding cycle S100, described below, is controlled by the controller 60.

[0056] A film-like insertion material 80 is prepared first. This insertion material 80 is preheated to its softening point or higher using the heater 86 of a heating device 85, independently of the injection molding cycle S100 described above (see Fig. 5A), heated up.

[0057] Furthermore, prior to the mold clamping step S100, the movable mold 42, which is supported by the movable support plate 33, is separated from the fixed mold 41, which is fixed by the fixed support plate 32 (mold opening is performed) (see Fig. 1) moved away.

[0058] In this state, the assembly device (transfer device) 87, which is, for example, an unloading device or a robot, is used to transfer the heated insertion material 80 (transfer step) and place it in the mold 40. In this case, the insertion material 80 is installed on the pair of shaft elements 46 of the fixed mold 41 and then bent in the mold 40 by the assembly device 87 (see Fig. 5b), deformed. At this point, one end 81 and the other end 82 of the insertion material 80 both hang downwards from the shaft elements 46.

[0059] It should be noted that while in the present embodiment the insertion material 80 is installed on the pair of shaft elements 46 of the fixed mold 41 and is subsequently deformed by the assembly device 87, which bends it into the mold 40, the method of the present invention is not limited to this. For example, it is instead possible to connect the pair of shaft elements 46 to the movable mold 42 and to place the insertion material on the pair of shaft elements 46 of the movable mold 42, followed by the deformation of the insertion material 80 by the assembly device 87 in the mold 40.

[0060] The insertion material 80 is then placed by the assembly device 87 at a predetermined position within the nest 44 of the mold 40. This means that one side of the other end 82 of the insertion material 80 is bent by the assembly device 87 so that it is wrapped around one of the shaft elements 46 and then onto the projection 47 (see Fig. 5C). Subsequently, one side of one end 81 of the insertion material 80 is bent by the assembly device 87 so that it is wrapped around the other shaft element 46 and then attached to the projection 47 (see Fig. 5D). At this point, one end 81 of the insertion material 80 is placed on top of the other end 82. The operations performed by the Fig. 5B, Fig. 5C and Fig. The steps represented in 5D are sometimes referred to as the placement step, in which the assembly device 87 is used to place the insertion material 80 in the shape 40, or as the deformation step, in which the assembly device 87 is used to deform the insertion material 80 in the shape 40.

[0061] It should be noted that while in the present invention the assembly device 87 is also used as a transfer device for transferring the heated insertion material 80, the present embodiment is not limited to this. Alternatively, the transfer device for transferring the insertion material 80 and the assembly device 87 can be designed as separate devices. In this case, the assembly device 87 can be one in which the insertion material 80 is mounted in the nest 44 by means of a sliding core or other actuation of the mold 40.

[0062] As shown above, the section that one end 81 of the insertion material overlaps must overlap on one part of the insertion material and not necessarily on the other end 82. Additionally, it is also possible to fold one end 81 (or the other end 82) of the insertion material 80 and glue the folded section of one end 81 (or the other end 82) to increase its strength.

[0063] Subsequently, when the movable form 42 moves towards the fixed form 41 and comes into close contact with the fixed form 41, the movable form 42 and the fixed form 41 are clamped (form clamping step S101) (see Fig. 5E). At this point, the cut 43, which is provided in the fixed form 41, is located inside the ring surrounded by the insertion material 80.

[0064] Next, a drive mechanism (not shown) moves the collecting plate 45 towards the nest 44, thereby moving the collecting plate 45 from the retracted position to the collecting position (see Fig. 5F) (catching step). At this point, the catching plate 45 is positioned such that it extends between the pair of shaft elements 46.

[0065] The following injection step S102 for the injection filling of the resin material forms a shaped product 70, which contains the introduction material 80. In this injection step S102, in which the movable mold 42 and the fixed mold 41 are clamped, the molten resin material is injected from the nozzle 24 of the injection device 20 and the mold 40 is filled with resin material.

[0066] It should be noted that while in the present embodiment the collecting plate 45 is moved from the retracted position to the collecting position shortly before the injection of the resin material, the present embodiment is not limited to this. For example, it is possible instead to move the collecting plate 45 from the retracted position to the collecting position when the feed material 80 is placed in the mold 40, or to stop the movement of the collecting plate 45 to the collecting position at the time the feed material 80 is placed in the mold 40. That is to say, it is only necessary that the collecting plate 45 is in the collecting position before the injection of the resin material.

[0067] In injection step S102 during the initial injection filling phase, the flow of resin material within the cavity is regulated by the collection plate 45. This means that the resin material first flows from gate 43 into the cavity 44 and then horizontally within the resin influence chamber 41 along a surface (top surface) of the collection plate 45. Next, while being controlled by the collection plate 45, the resin material flows along one side (upstream flow paths 53a) from the separation chambers 52 (see arrows in Fig. 5F) in the direction of the flow paths 53a. On the other hand, the resin material will not flow directly from the diverging flow spaces 52 into the flow paths 53b on the other side (downstream flow paths 53b). As above, the resin material flows through the flow paths 53a on one side, the intersection section 54, the flow paths 53b on the other side in that order, and then flows along the other side of the other surface (bottom surface) of the collection plate 45 to flow into the resin influence space 51.

[0068] During this time, the insertion material moves, expanding towards the outer side using the resin material flowing within nest 44, and is in a predetermined position along the inner surface of nest 44 (see Fig. 5F). At this point, while one end 81 and the other end 82 of the injection material 80 move relative to each other, so that the width of the overlap section becomes small, one end 81 and the other end 82 remain in an overlapping state even after the filling with the resin material is complete. Consequently, when the cavity is filled with the resin material, the overlapping section between one end 81 and the other end 82 is pressed and bonded (pressure-joined) by the pressure of the resin material. Consequently, injection step S102 is also referred to as the bonding step.

[0069] Next, a drive mechanism (not shown) pulls the collecting plate 45 into the movable form 42 to hold the collecting plate 45 in the retracted position (see Fig. 5G). The point in time at which the collection plate 45 is moved into the retracted position is, for example, when the entire space in the nest 44, with the exception of the collection plate 45, has been filled with resin material. The exact timing of this can be controlled in accordance with the position of the screw 23 within the cylinder 22 or the length of time that has elapsed since the resin material was injected from the nozzle 24.

[0070] Subsequently, continuing the injection operation using the injection device 20 forces the resin material into the space in the nest 44 where the collecting plate 45 was located (the space is defined by the two-dotted dashed line of Fig. 5 made visible). Consequently, the resin material runs apart at the opposite positions of the gate 43 with respect to the collecting plate 45 and the position corresponding to the collecting plate 45, thereby forming the weld line W (see Fig. 3).

[0071] The dwell and cooling step S103 then results in the production of the shaped product 70, which is in Fig. Figure 3 represents the process. The mold 40 is then opened in the mold opening step S104. In the product unloading step S105, the molded product 70 is ejected from the movable mold 42, and as a result of the removal of the molded product 70, the injection molding cycle S100 is complete. The injection step S102 and / or the dwell and cooling step S103 are examples of the molding process.

[0072] As described above, according to the present embodiment, in injection step S102, the flow of the resin material within the cavity 44 is controlled by the collecting plate 45 in an initial phase of the injection filling, and subsequently the collecting plate 45 is drawn into the movable mold 42. Consequently, the weld line W can be formed away from the parts that tend to have lower strength in the molded product 70 (for example, the branch sections 75a and 75b and the connecting section 76), thereby improving the strength of these parts. As a result of the higher strength, a reduction in the local strength of the molded product 70 due to a weld line W can be prevented.Additionally, because optimal molding conditions (the positions, shapes, and effective path cross-sectional areas of the sprue and gate, and the temperature and flow rate of the flowing material [resin]) do not need to be found by trial and error to shift the weld line position, the molding conditions for the molded product 70 can be easily determined. Furthermore, during injection filling, turbulent flow through the molten resin is also induced at the part forming the weld line W (the space where the catch plate 45 was located), consequently reducing the decrease in the strength of the molded product 70.

[0073] Furthermore, according to the present embodiment, the resin material is injected into the mold 40, while one end 81 and the other end 82 of the injected material 80 overlap, thereby bonding the overlapping end 81 and the other end 82 together. This operation prevents a reduction in local strength in the molded product 70 and further prevents a reduction in strength due to a loose connection at the joint or the like.

[0074] Furthermore, according to the present embodiment, the insertion material 80, after being deformed within the mold 40, is positioned, and in this state, the resin material is injected into the mold 40, so that the formed product 70 incorporates the insertion material 80. Consequently, when the film-like insertion material 80 is placed in the mold 40, it can be easily positioned in a predetermined location after deformation. Additionally, because the resin material is injected into the softened insertion material 80, the adhesive strength between the insertion material 80 and the resin material (more precisely, the adhesive strength between the insertion material 80 and the resin at their common surface) can be increased.

[0075] Furthermore, according to the present embodiment, at the time the formed product 70 is formed, the insertion material 80 is transferred into the mold 40 and then deformed within the mold 40, followed by the injection of the resin material into the mold. Consequently, the process of forming the formed product 80 can be simpler than if both a process in which the insertion material 80 is formed by compression molding and a further process in which the formed insertion material 80 is inserted into the mold 40 are carried out. Modification example

[0076] While the above-described shaped product 70 presents an example in which the insertion material 80 surrounds the material section 71, the invention is not limited thereto. For example, as in Fig. As shown in Figure 6, the insertion material 80 can instead be placed within the material section 71.

[0077] In Fig. 6 the formed product 70 includes the material section 71, which includes a synthetic resin and the insertion material 80, which is integrally formed in the material section 71.

[0078] The insertion material 80 is positioned so that it extends from a longitudinal direction (Y-direction) of the formed main product body section 73 to the substantially central section of a lateral direction (Z-direction) of the formed main product body section 73. Since, in this case, the weld line W is not formed or is only very slight on the formed product 70, the local strength of the formed product 70 is prevented from being reduced due to the weld line W. Additionally, because the insertion material 80 is positioned to surround the pair of through holes 77, the strength near the through holes 77 can be improved. Furthermore, one end 81 and the other end 82 of the insertion material 80 are glued together, with the two ends overlapping within the formed main product body section 73.

[0079] To create the shaped product 70, which is in Fig. As shown in Figure 6, after the insertion material 80 has been wrapped around the pair of shaft elements 46, the assembly device 87 is used, for example, to press the upper section of the insertion material 80 downwards (see Figure 6). Fig. 7A) (one pressing step). Consequently, the gate 43 is located outside the annular insertion material 80 (see Fig. 7B). It is noted that Fig. 7A and Fig. 7B Fig. 5D and Fig. 5E each correspond.

[0080] The injection filling process in this state ensures that the resin material flows along the outer surface of the insertion material 80 and through the flow paths 53a on one side, the intersection section 54, and the flow paths 53b on the other side, eventually reaching below the insertion material 80. During this operation, the insertion material 80 is moved by the resin material flow within the nest 44 toward the center and into a predetermined position, which is defined in Fig. As shown in Figure 6, the overlapping section between one end 81 and the other end 82 of the insertion material 80 is pressed and bonded (pressure joined) by the pressure of the resin material.

[0081] In the production of the shaped product 70, which is in Fig. As shown in Figure 6, the use of the collection plate 45 is optional. If the collection plate 45 is not used, the resin material flow into the cavity 44 is controlled by the gate 43, so that the resin material flows in the direction of the flow paths 53a, passing on one side of the insertion material 80 along a surface (top surface) of the insertion material 80. In this case, the use of the insertion material 80 prevents the local strength of the molded product 70 from decreasing due to the weld line W.

[0082] It should be noted that the formed product production device of the present embodiment of the invention is not limited to an injection molding machine. For example, the device may instead be a metal casting machine (device for producing formed products or forming device) such as a die casting machine (device for producing formed products or forming device) or the like, or another plastic forming machine (device for producing formed products or forming device) such as an injection molding machine (device for producing formed products or forming device) or the like.

[0083] Some of the components disclosed in the above embodiments can also be usefully combined if required. Alternatively, some components disclosed in the above embodiments can be omitted.

Claims

[1] Device for producing shaped products (70) using a film-like insertion material (80), the device comprising: a transfer device (87) for transferring the insertion material (80) into a mold (40); and an injection device (20) for injecting a molding material into the mold, wherein the injection device (20) is set up to inject the molding material into the mold when the insertion material (80) has been deformed inside the mold (40), and the transfer device (87) is set up to deform the insertion material (80) within the mold (40) such that one end of the insertion material overlaps with a part of the insertion material. [2] Method for producing a shaped product using a film-like insertion material, the method comprising: a transfer step to transfer the insertion material (80) into a mold (40) using a transfer device (87); a placement step for placing the insertion material (80) into the mold (40) by deforming the insertion material in the mold; and a forming step for injecting a forming material into the mold, thereby producing the formed product which has the insertion material (80), wherein the placement step includes a deformation step to overlap one end of the insertion material (80) with a portion of the insertion material (80) in the mold using the transfer device (87). [3] Method according to claim 2, wherein by injecting the molding material into the mold during the molding step the end of the insertion material (80) and the part of the insertion material that overlaps with each other are bonded together. [4] Method according to claim 2, wherein the insertion material (80) comprises one end (81) and another end (82), and wherein one end (81) of the insertion material overlaps with the other end (82) of the insertion material during the deformation step. [5] Method according to claim 2, wherein during the deformation step the end of the insertion material is folded onto itself, thereby layering the end. [6] Method according to any one of claims 2 to 5, wherein the forming material converges in an area where the end of the insertion material and the part of the insertion material overlap. [7] Formed product, comprising: a material section (71); and an insertion material (80) that is integrally formed with the material section, wherein the insertion material (80) is bent and one end of the insertion material (80) overlaps with part of the insertion material (80), wherein the end of the insertion material (80) and the part of the insertion material (80) that overlaps with each other are glued together and the insertion material (80) is arranged such that it surrounds an outer section of the material section (71) while it is bent.

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