Method for manufacturing molded article

Abstract

To provide a technique for reducing a labor of integrating a first member and a second member, when the first member is mounted on other member using the second member.SOLUTION: There is provided a method for manufacturing a molded article which is integrally molded using a first member and a second member having flowability. A first mold has: a base part; a side wall part extending from the base part; an installation surface which forms an internal space that is adjacent to the base part and is surrounded by the side wall part; and an insertion part provided on the installation surface. A method for manufacturing a molded article includes: inserting an extension part extending from a body part of a second member into an insertion part; and arranging a first member in the internal space. The method for manufacturing a molded article also includes bringing the first mold and a second mold into contact with each other, press molding the first member so as to cover the body part with the first member, and molding a molded article.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a method for producing a molded article. [Background technology]

[0002] Patent document 1 discloses that when attaching a composite wear-resistant component to a mounting material, a bolt is fitted into a mounting hole provided in the composite wear-resistant component, and the composite wear-resistant component and the bolt are fixed together to the mounting material. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2014-237166 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the above-mentioned fixing method, it is necessary to provide a mounting hole in the composite wear-resistant member and fit the bolt into the mounting hole, which causes a problem that it is time-consuming to integrate the composite wear-resistant member and the bolt, which are separate members.

[0005] An object of one aspect of the present disclosure is to provide a technique for reducing the effort required to integrate a first member and a second member when attaching a first member to another member using a second member. [Means for solving the problem]

[0006] One aspect of the present disclosure is a method for manufacturing a molded product integrally molded using a first member and a second member. The first member is a member having fluidity. The second member has a main body portion and an extension portion. The extension portion extends from the main body portion. The first mold has a base portion, a side wall portion, an installation surface, and an insertion portion. The side wall portion is a portion extending from the base portion. The installation surface is an internal space adjacent to the base portion, and forms an internal space surrounded by the side wall portion. The insertion portion is provided on the installation surface. The second mold is disposed so as to face the first mold. The method for manufacturing a molded product includes inserting the extension portion into the insertion portion and arranging the main body portion in the internal space. The method for manufacturing a molded product also includes arranging the first member in the internal space. The method for manufacturing a molded product also includes bringing the first mold and the second mold close to each other, and press-molding the first member so that the main body portion is covered by the first member to mold the molded product.

[0007] According to this configuration, a molded product formed integrally using the first member and the second member can be obtained by press molding, thereby reducing the effort required to integrate the first member and the second member when attaching the molded first member to another member using the second member.

[0008] In one embodiment of the present disclosure, the second mold may have a pressing portion. The manufacturing method of the molded product may further include pressing the main body portion toward the insertion portion by the pressing portion when press-molding the first member. According to this configuration, the second member is made less likely to move by the pressing of the pressing portion, so that it is possible to suppress the position of the second member from changing due to the pressure generated by the press molding of the first member.

[0009] In one aspect of the present disclosure, the second member may be disposed in the internal space such that the insertion portion is covered by the main body portion. With this configuration, the insertion portion is covered by the main body portion, so that it is possible to prevent the first member from entering the insertion portion.

[0010] In one embodiment of the present disclosure, the second member may be a bolt. With this configuration, a molded product can be obtained that is integrally molded using the first member and the bolt.

[0011] In one aspect of the present disclosure, an inclusion may be provided between the installation surface and the opposing surface of the body of the bolt, the opposing surface being opposed to the installation surface of the body, so as to surround the insertion portion. The inclusion may be located inside the outer edge of the opposing surface. In this configuration, a gap into which the first member can enter is formed between the opposing surface of the body of the bolt and the installation surface of the first mold. When the first member solidifies with the first member in the gap, the first member that has entered the gap holds the body from the opposing surface side. This makes it possible to prevent the bolt from falling off the first member.

[0012] In one aspect of the present disclosure, the first member may be a semi-solidified metal material, a resin material, or a resin composite material. With this configuration, a molded product can be obtained that is integrally molded with the second member using the semi-solidified metal material, the resin material, or the resin composite material. [Brief description of the drawings]

[0013] [Figure 1] FIG. 2 is a diagram showing a schematic structure of a press molding apparatus. [Diagram 2] FIG. 2 is a diagram showing a molded product molded by a press molding device. [Diagram 3] Fig. 3A is a diagram showing a first arrangement step, Fig. 3B is a diagram showing a second arrangement step, Fig. 3C is a diagram showing a sealing step, Fig. 3D is a diagram showing a pressing step, and Fig. 3E is a diagram showing a removal step. [Figure 4] 4 is a top view illustrating a schematic view of a position of a first member relative to an insertion hole provided in a first mold. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. [1. Configuration of press molding equipment] The press molding apparatus 100 shown in Fig. 1 is an apparatus for producing a molded product 200 shown in Fig. 2 by press molding using a first die 1 and a second die 2 described below. In this embodiment, the molded product 200 is formed by integrally molding a first member 5, a second member 6, and an inclusion 7.

[0015] The first member 5 before molding is a member having fluidity. For example, a semi-solidified aluminum material, which is a semi-solidified metal material, is used for the first member 5. The metal type of the semi-solidified metal material is not limited to aluminum, and various other metals (magnesium, as one example) can be used. The first member 5 after molding, that is, the first member 5 in the molded product 200, is in a solidified state due to cooling, in other words, in a state having no fluidity.

[0016] The second member 6 is a member for attaching the first member 5 in the molded product 200 to another member. As shown in Fig. 2, the second member 6 has a main body 61 and an extension 62. The main body 61 is a surface that extends substantially horizontally, and has a bottom surface 611 that faces an upper surface 111 of the first mold 1 described below. The extension 62 is rod-shaped, and extends from the main body 61 substantially perpendicularly to the bottom surface 611. For the second member 6, for example, a bolt having a flange is used.

[0017] The inclusion 7 is annular, and is disposed on the second member 6 so as to go around the outer circumferential surface of the extension portion 62. The inclusion 7 is sandwiched between a bottom surface 611 of the main body portion 61 and an upper surface 111 of the first mold 1 described below. The inclusion 7 is located inside the outer edge of the bottom surface 611 of the main body portion 61. The inclusion 7 may be, for example, a washer.

[0018] 1, the press molding apparatus 100 includes a first die 1, a second die 2, a slide 3, and a bolster 4. In the following description, the directions of up / down, left / right, and front / rear are used for convenience of explanation and do not limit the manner of use of the press molding apparatus 100.

[0019] The first die 1 and the second die 2 are arranged to face each other in the vertical direction. In this embodiment, the first die 1 is located at the bottom, and the second die 2 is located at the top. Specifically, the second die 2 is fixed to the bottom surface of a slide 3 that moves in the vertical direction by a motor or the like, and the first die 1 is fixed to the top surface of a bolster 4 that is arranged below the slide 3. In this embodiment, press working is performed by the first die 1 and the second die 2 by moving the second die 2 in the vertical direction.

[0020] The first mold 1 is in the shape of a box that is open at the top, and has a base 11, a side wall 12, and an insertion hole 13. The base 11 faces the second mold 2. The side wall 12 extends upward from the edge of the base 11 and is provided so as to go around the base 11. The upper end of the side wall 12 surrounds the opening of the first mold 1.

[0021] In the first mold 1, a rectangular parallelepiped internal space 14 is formed adjacent to the base 11 and surrounded by the side wall 12. Specifically, the internal space 14 is formed by an upper surface 111 of the base 11 and an inner peripheral surface 121 of the side wall 12. The upper surface 111 extends substantially horizontally, and the inner peripheral surface 121 extends substantially perpendicular to the upper surface 111. The shape of the internal space is determined appropriately depending on the shape of the molded product. The second mold 2 can be inserted into the internal space 14.

[0022] The insertion hole 13 forms a cylindrical insertion space. In this embodiment, the insertion hole 13 is provided on the upper surface 111 of the base 11, and extends downward from the upper surface 111 in a substantially linear manner. The insertion hole 13 may or may not penetrate the base 11. The above-mentioned extension portion 62 of the second member 6 can be inserted into the insertion hole 13, and the insertion hole 13 is covered by the main body portion 61 of the second member 6. The shape of the insertion hole is determined appropriately according to the shape of the extension portion.

[0023] The second mold 2 has a mold main body portion 21, a pressing portion 22, and an elastic portion . The mold body 21 is rectangular and has a lower surface 211, a side surface 212, and a storage hole 213. The lower surface 211 is a surface facing the upper surface 111 of the first mold 1, and extends substantially horizontally. The side surface 212 extends upward from the edge of the lower surface 211, substantially perpendicular to the lower surface 211, and is provided so as to go around the lower surface 211. The storage hole 213 forms a rectangular storage space. In this embodiment, the storage hole 213 is provided at a position facing the insertion hole 13 of the first mold 1 on the lower surface 211 of the mold body 21, and extends upward from the lower surface 211. The mold body 21 is inserted into the internal space 14 of the first mold 1 so that the side surface 212 faces the inner peripheral surface 121 of the first mold 1 with almost no gap formed.

[0024] The pressing portion 22 has a rectangular parallelepiped shape that is substantially the same as the accommodation hole 213, and can be accommodated in the accommodation hole 213 with almost no gap formed. The pressing portion 22 is connected to the mold main body 21 via the elastic portion 23. A protruding portion 222 that protrudes downward is formed on the lower surface 221 of the pressing portion 22. When the pressing portion 22 is accommodated in the accommodation hole 213, the lower surface 221 of the pressing portion 22 spreads in the same plane as the lower surface 211 of the mold main body 21, and the protruding portion 222 protrudes from the plane. The shape of the pressing portion is determined appropriately according to the shape of the accommodation hole.

[0025] The elastic portion 23 is disposed in the accommodation hole 213, and the upper end is fixed to the mold body portion 21, and the lower end is fixed to the pressing portion 22. For example, a spring is used for the elastic portion 23. For example, a gas cushion may be used for the elastic portion. The pressing portion 22 can be displaced in the vertical direction by the expansion and contraction of the elastic portion 23, and can protrude from the accommodation hole 213 or be accommodated in the accommodation hole 213. In this embodiment, when the second mold 2 is separated from the first mold 1, the pressing portion 22 is maintained in a state in which a part or the whole of the pressing portion 22 protrudes from the accommodation hole 213 due to the elastic force of the elastic portion 23. When a force in a direction to push the pressing portion 22 into the accommodation hole 213 is applied to the pressing portion 22, the elastic portion 23 contracts, and the pressing portion 22 is accommodated in the accommodation hole 213.

[0026] [2. Manufacturing method of molded products using press molding equipment] 3A to 3E, a manufacturing method of the molded product 200 by the above-mentioned press molding apparatus 100 will be described. In this embodiment, the molded product 200 is manufactured by integrally molding the first member 5, the second member 6, and the inclusion 7 by press molding. The manufacturing method of the molded product 200 in this embodiment includes a first arrangement step, a second arrangement step, a sealing step, a pressing step, and a removal step.

[0027] <First placement process> First, as shown in FIG. 3A, the second member 6 and the inclusion 7 are placed in the internal space 14 of the first mold 1. Specifically, in a state in which the inclusion 7 surrounds the insertion hole 13 of the first mold 1 and the inclusion 7 is placed between the bottom surface 611 of the second member 6 and the upper surface 111 of the first mold 1, the extension portion 62 of the second member 6 is inserted into the insertion hole 13 of the first mold 1. At this time, the main body portion 61 of the second member 6 is placed in the internal space 14 so as to cover the insertion hole 13. As shown in FIG. 4, for example, in the case where two insertion holes 13 arranged in front and behind are provided in the right side region of the upper surface 111 of the first mold 1, one inclusion 7 is placed so as to surround each insertion hole 13, and one extension portion 62 of the second member 6 is inserted into each insertion hole 13.

[0028] <Second placement process> Next, as shown in Fig. 3B, the first member 5 is placed in the internal space 14. Specifically, as shown in Fig. 4, the first member 5 is placed in the left region on the upper surface 111 of the first mold 1, that is, at a position on the upper surface 111 of the first mold 1 that does not overlap with the two insertion holes 13. In other words, the first member 5 is placed in the internal space 14 so as not to overlap with the two second members 6 inserted into the insertion holes 13.

[0029] <Sealing process> Next, as shown in FIG. 3C, the first mold 1 and the second mold 2 are brought close to each other, and the pressing portion 22 of the second mold 2 presses the main body 61 of the second member 6 toward the insertion hole 13. Specifically, the second mold 2 is lowered, and the protruding portion 222 of the pressing portion 22 is brought into contact with the main body 61 of the second member 6, and the main body 61 is pressed downward. At this time, the main body 61 also presses the intermediate member 7 arranged between the bottom surface 611 of the main body 61 and the upper surface 111 of the first mold 1 downward. As a result, the main body 61 of the second member 6 and the intermediate member 7 seal the insertion hole 13. At this time, the pressing portion 22 is in a state of protruding downward from the accommodation hole 213, and the lower surface 211 of the mold main body 21 in the second mold 2 is located above the lower surface 221 of the pressing portion 22. For this reason, when the protruding portion 222 of the pressing portion 22 comes into contact with the main body portion 61, the lower surface 211 of the mold main body portion 21 does not come into contact with the first member 5. That is, in this embodiment, the main body portion 61 of the second member 6 is pressed by the pressing portion 22 even before the first member 5 is press-molded by the second mold 2, and the insertion hole 13 is sealed by the main body portion 61 and the inclusion 7.

[0030] <Pressing process> Next, as shown in FIG. 3D, the first mold 1 and the second mold 2 are brought closer to each other, and the first member 5 is press-molded so that the main body 61 of the second member 6 is covered by the first member 5. Specifically, the first member 5 is pressed by the lower surface 211 of the mold main body 21, and the second mold 2 is lowered until the lower surface 211 of the mold main body 21 and the lower surface 221 of the pressing portion 22 in the second mold 2 are flush with each other. At this time, the pressing portion 22 is accommodated in the accommodation hole 213 by the contraction of the elastic portion 23. As a result, the lower surface 211 of the mold main body 21 and the lower surface 221 of the pressing portion 22 are flush with each other. Even during the press molding of the first member 5 by the mold main body 21, the main body 61 of the second member 6 continues to be pressed by the pressing portion 22, and the sealing of the insertion hole 13 by the main body 61 and the inclusion 7 continues. That is, the sealing process continues during the pressing process.

[0031] The first member 5 is deformed by being pressed, and is filled into the molding space closed by the first mold 1 and the second mold 2. Specifically, the first member 5 flows into the gap between the upper surface of the main body 61 of the second member 6 and the lower surface 221 of the pressing portion 22, and into the gap between the bottom surface 611 of the main body 61 and the upper surface 111 of the first mold 1. As a result, the main body 61 of the second member 6 and the inclusions 7 are covered by the first member 5. Then, while the relative distance between the first mold 1 and the second mold 2 is maintained, the deformed first member 5 is cooled, and the molded product 200 is molded.

[0032] <Removal process> 3E, the first mold 1 and the second mold 2 are pulled apart, and the second mold 2 is removed from the molded product 200. Thereafter, the molded product 200 is removed from the first mold 1. This completes the production of the molded product 200 in which the first member 5, the second member 6, and the inclusion 7 are molded integrally with each other, with the main body 61 of the second member 6 and the inclusion 7 embedded in the first member 5 and the extension portion 62 of the second member 6 protruding from the first member 5.

[0033] [3. Effects] According to the embodiment described above in detail, the following effects can be obtained. (3a) In this embodiment, a molded product 200 is obtained by molding the first member 5 integrally with the first member 5 and the second member 6 through press molding by the press molding apparatus 100. Therefore, when attaching the molded first member 5 to another member using the second member 6, the effort required to integrate the first member 5 and the second member 6 can be reduced.

[0034] (3b) When the first member 5 is deformed by press molding, the first member 5 is filled into the molding space closed by the first die 1 and the second die 2. At this time, the first member 5 that has flowed into the periphery of the second member 6 may generate pressure in a direction that causes the second member 6 to float upward.

[0035] However, in this embodiment, when the first member 5 is press-molded, the main body 61 of the second member 6 is pressed toward the insertion hole 13 by the pressing portion 22 of the second die 2. Furthermore, the insertion hole 13 of the first die 1 is covered by the main body 61 of the second member 6 and the inclusion 7 with the extension portion 62 of the second member 6 inserted therein.

[0036] For this reason, even if the above-mentioned pressure is generated, it is possible to maintain the insertion hole 13 in a closed state by the main body portion 61 of the second member 6. As a result, it is possible to prevent the first member 5 from entering the insertion hole 13.

[0037] In addition, since the second member 6 is less likely to move due to the pressure of the pressing portion 22, even if the above-mentioned pressure is generated, the position of the second member 6 can be prevented from changing. As a result, the accuracy of the position where the second member 6 is provided in the molded product 200 can be improved.

[0038] (3c) In this embodiment, an inclusion 7 is disposed between the bottom surface 611 of the main body 61 of the second member 6 and the top surface 111 of the first mold 1, the inclusion 7 being located inside the outer edge of the bottom surface 611. This forms a gap between the bottom surface 611 and the top surface 111 into which the first member 5 can enter. When the first member 5 deforms and enters the gap, and the first member 5 solidifies in this state, the main body 61 of the second member 6 is held from the bottom surface 611 side by the first member 5 that has entered the gap. This makes it possible to prevent the second member 6 from falling off the first member 5.

[0039] In this embodiment, the bottom surface 611 of the main body 61 corresponds to an example of an opposing surface, the top surface 111 of the base 11 corresponds to an example of an installation surface, and the insertion hole 13 corresponds to an example of an insertion portion.

[0040] [4. Other embodiments] Although the embodiments of the present disclosure have been described above, it goes without saying that the present disclosure is not limited to the above-described embodiments and can take various forms.

[0041] (4a) In the above embodiment, a semi-solid metal material is used as the first member 5, but the material of the first member is not limited to this. For example, the first member may be a resin material or a resin composite material that is a composite material of resin and fiber.

[0042] (4b) In the above embodiment, a bolt having a flange is used as the second member 6, but the second member is not limited to a bolt having a flange. For example, the second member may be a bolt without a flange or various other members.

[0043] (4c) In the above embodiment, a configuration is illustrated in which two insertion holes 13 are arranged in a front-to-back manner in the right-hand region of the upper surface 111 of the first mold 1. However, the number and positions of the insertion holes are not limited to this and may be determined as appropriate.

[0044] (4d) In the above embodiment, a washer is used as the inclusion 7, but the inclusion disposed between the bottom surface 611 of the second member 6 and the upper surface 111 of the first mold 1 is not limited to this. For example, the inclusion may be a convex portion provided on the bottom surface of the second member so as to protrude downward, surrounding the extension portion 62 and located inside the outer edge of the main body of the second member. Also, for example, the inclusion may be a convex portion provided on the upper surface of the first mold so as to protrude upward, surrounding the insertion hole and located inside the outer edge of the main body of the second member.

[0045] (4e) In the above embodiment, the second mold 2 has the pressing portion 22, and the main body portion 61 of the second member 6 is pressed by the pressing portion 22 before the first member 5 is press-molded by the second mold 2. That is, the manufacturing method in which the sealing process is started before the pressing process is exemplified. However, for example, the main body portion 61 of the second member 6 may be pressed by the pressing portion 22 at the same timing as the pressing of the first member 5 by the second mold 2. That is, the pressing process and the sealing process may be started at the same timing. Also, for example, the main body portion 61 of the second member 6 may be pressed by the pressing portion 22 slightly later than the pressing of the first member 5 by the second mold 2. That is, the sealing process may be started slightly later than the start timing of the pressing process.

[0046] Also, for example, the second mold may not have a pressing portion. That is, the manufacturing method of the molded product may not include a sealing step. In this case, in the above embodiment, the insertion hole 13 is provided on the upper surface 111 of the first mold 1, but for example, the insertion hole may be provided on the inner peripheral surface of the side wall portion of the first mold.

[0047] (4f) In the above embodiment, the insertion hole 13 is covered by the main body portion 61 of the second member 6. However, for example, the second member does not have to cover the insertion hole 13 with the main body portion.

[0048] (4g) The function of one component in the above embodiments may be distributed among multiple components, or the functions of multiple components may be integrated into one component. Also, part of the configuration of the above embodiments may be omitted. Also, at least part of the configuration of the above embodiments may be added to or substituted for the configuration of another of the above embodiments. [5. Technical Concepts Disclosed in This Specification]

[0049] [Item 1] A method for manufacturing a molded product integrally formed using a first member and a second member, comprising the steps of: the first member is a member having flowability, The second member has a main body portion and an extension portion extending from the main body portion, a first mold having a base, a side wall extending from the base, an installation surface that forms an internal space adjacent to the base and surrounded by the side wall, and an insertion portion provided on the installation surface; inserting the extension portion into the insertion portion and arranging the main body portion in the internal space; disposing the first member in the internal space; bringing the first die and a second die arranged to face the first die closer to each other, and press-molding the first member so that the main body portion is covered by the first member, thereby molding the molded product; A method for manufacturing a molded product comprising the steps of:

[0050] [Item 2] A method for producing the molded article according to item 1, The second mold has a pressing portion, The method for manufacturing a molded product further comprises pressing the main body portion toward the insertion portion with the pressing portion when press molding the first member.

[0051] [Item 3] A method for producing a molded article according to item 1 or 2, A method for manufacturing a molded product, wherein the second member is placed in the internal space so that the main body portion covers the insertion portion.

[0052] [Item 4] A method for producing a molded article according to any one of items 1 to 3, A method for manufacturing a molded product, wherein the second member is a bolt.

[0053] [Item 5] A method for producing a molded article according to item 4, An interposition member is provided between an opposing surface of the main body portion of the bolt that faces the installation surface and the installation surface, the interposition member being arranged so as to surround the insertion portion, A method for manufacturing a molded product, wherein the inclusion is located inside the outer edge of the opposing surface.

[0054] [Item 6] A method for producing a molded article according to any one of items 1 to 5, The method for manufacturing a molded product, wherein the first member is a semi-solid metal material, a resin material, or a resin composite material. [Explanation of symbols]

[0055] 1...first mold, 2...second mold, 3...slide, 4...bolster, 5...first member, 6...second member, 7...inclusion, 11...base, 12...side wall portion, 13...insertion hole, 14...internal space, 21...mold main body portion, 22...pressing portion, 23...elastic portion, 61...main body portion, 62...extension portion, 100...press molding apparatus, 111...upper surface, 121...inner surface, 200...molded product, 211, 221...lower surface, 212...side surface, 213...accommodating hole, 222...protrusion, 611...bottom surface.

Claims

1. A method for manufacturing a molded product integrally molded using a first member and a second member, comprising the steps of: the first member is a member having flowability, The second member has a main body portion and an extension portion extending from the main body portion, a first mold having a base, a side wall extending from the base, an installation surface that forms an internal space adjacent to the base and surrounded by the side wall, and an insertion portion provided on the installation surface; inserting the extension portion into the insertion portion and arranging the main body portion in the internal space; disposing the first member in the internal space; bringing the first die and a second die arranged to face the first die closer to each other, and press-molding the first member so that the main body portion is covered by the first member to mold the molded product; A method for manufacturing a molded product comprising the steps of:

2. A method for producing the molded article according to claim 1, The second mold has a pressing portion, The method for manufacturing a molded product further comprises pressing the main body portion toward the insertion portion by the pressing portion when press molding the first member.

3. A method for producing the molded article according to claim 1 or 2, comprising the steps of: A method for manufacturing a molded product, wherein the second member is placed in the internal space so that the main body portion covers the insertion portion.

4. A method for producing the molded article according to claim 1 or 2, comprising the steps of: A method for manufacturing a molded product, wherein the second member is a bolt.

5. A method for producing the molded article according to claim 4, comprising the steps of: An interposition member is provided between an opposing surface of the main body portion of the bolt that faces the installation surface and the installation surface, the interposition member being arranged so as to surround the insertion portion, A method for manufacturing a molded product, wherein the inclusion is located inside the outer edge of the opposing surface.

6. A method for producing the molded article according to claim 1 or 2, comprising the steps of: The method for manufacturing a molded product, wherein the first member is a semi-solid metal material, a resin material, or a resin composite material.

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