Method and apparatus of manufacturing article

Abstract

To provide a method and an apparatus of manufacturing an article that enable complicated molding.SOLUTION: A method of manufacturing a molded article has the steps of: mold-closing a first die and an intermediate die in a state in which a surface-A is placed opposite a first surface and injecting a molten resin into the die to mold a first component and a second component between the first surface and the surface-A; engaging the second component with the first component held on the surface-A while mold-closing the first die and the intermediate die in a state in which a surface-B is placed opposite the first surface and injecting the molten resin into the die to mold a third component and a fourth component between the first surface and the surface-B; engaging the fourth component with the third component held on the surface-B while mold-closing the second die and the intermediate die in a state in which the surface-A is placed opposite a second surface and injecting the molten resin into the die to weld the first component and the second component together to mold a first integrated molded article; mold-closing the second die and the intermediate die in a state in which the surface-B is placed opposite the second surface and injecting the molten resin into the die to weld the third component and the fourth component together to mold a second integrated molded article.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a method and an apparatus for manufacturing a molded product. [Background technology]

[0002] Patent Document 1 discloses a manufacturing apparatus equipped with an intermediate mold between a first mold and a second mold. In the manufacturing apparatus of Patent Document 1, in a first step, molding is performed using the first mold and the intermediate mold, and the intermediate mold is rotated 90° while leaving the molded products in the intermediate mold. In a second step, the molded products are assembled together in the intermediate mold, and the intermediate mold is rotated 90°. In a third step, the assembled molded products are joined using molten resin between the second mold and the intermediate mold, and the intermediate mold is rotated 90°. Finally, in a fourth step, the joined molded products are ejected from the intermediate mold. The first to fourth steps are then performed sequentially, shifting each step along the four faces of the intermediate mold. This allows each step to be performed simultaneously, improving productivity. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] European Patent No. 1628819 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the manufacturing device in Patent Document 1 is designed to manufacture multiple products of one type, and does not describe molding of two or more types of products. Furthermore, while the manufacturing device in Patent Document 1 can combine two molded parts, it cannot mold a combination of three parts, and is therefore unable to handle more complex molding.

[0005] Therefore, the present invention provides a method and apparatus for manufacturing a molded product that is capable of performing complex molding. [Means for solving the problem]

[0006] Therefore, the molded product manufacturing method of the present invention is a molded product manufacturing method using a first mold having a first surface, a second mold having a second surface, and an intermediate mold having surfaces A, B, C, and D that can face the first and second surfaces, and that can change the surfaces that face the first and second surfaces by rotating between the first mold and the second mold, and includes a first molding step of molding a first part and a second part between the first surface and the A surface by closing the first mold and the intermediate mold with the A surface facing the first surface and injecting molten resin into the mold, and a second molding step of molding a first part and a second part between the first surface and the A surface by closing the first mold and the intermediate mold with the B surface facing the first surface and injecting molten resin into the mold. a second molding step of engaging the second part with the first part held on surface A while molding a third part and a fourth part between the first part and the fourth part; a third molding step of closing the second mold and the intermediate mold with surface A facing the second surface and injecting molten resin into the molds to weld the first part and the second part together to form a first integrally molded product while engaging the fourth part with the third part held on surface B; and a fourth molding step of closing the second mold and the intermediate mold with surface B facing the second surface and injecting molten resin into the molds to weld the third part and the fourth part together to form a second integrally molded product different from the first integrally molded product. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a molded product manufacturing method and manufacturing apparatus that are capable of performing complex molding. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic diagram showing a manufacturing apparatus equipped with a rotatable intermediate mold. [Figure 2] 1 is a schematic diagram showing a finished molded product that can be molded by the manufacturing device. [Figure 3]FIG. 1 is an image diagram showing a molded product in which multiple parts are assembled in a conventional manufacturing device. [Figure 4] FIG. 2 is a schematic diagram showing the manufacturing apparatus and the regions on each side of the intermediate mold. [Figure 5] FIG. 2 is a diagram showing a manufacturing apparatus, a first surface of a first mold, and a second surface of a second mold. [Figure 6] FIG. [Figure 7] FIG. 1 is an image diagram showing a molded product. [Figure 8] FIG. 2 is a schematic diagram showing the first mold, intermediate mold, and second mold in the first step. [Figure 9] FIG. 10 is a schematic diagram showing the first mold, the intermediate mold, and the second mold in the second step. [Figure 10] 10A to 10C are diagrams illustrating a molding process in a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0009] (First embodiment) A first embodiment of the present invention will be described below with reference to the drawings.

[0010] 1 is a schematic diagram showing a manufacturing apparatus 100 equipped with a rotatable intermediate mold (intermediate die) according to the present invention. The manufacturing apparatus 100 includes a first mold 03, a second mold 04, and an intermediate mold 05, with the intermediate mold 05 being disposed between the first mold 03 and the second mold 04. The intermediate mold 05 has four surfaces that can face the first mold 03 and the second mold 04, and by rotating it every 90°, the surfaces that face the first mold 03 and the second mold 04 can be changed. Molding can be performed by closing the first mold 03 and the second mold 04 against the intermediate mold 05.

[0011] The first mold 03 is fixed to a fixed platen 01, which is fixed to an end of a linear slide 90. The second mold 04 is fixed to a movable platen 02, which is supported by the linear slide 90 so as to be movable on the linear slide 90. An injection unit 06 is provided on the fixed platen 01, and the injection unit 06 injects molten resin into the first mold 03. An injection unit 07 is provided on the movable platen 02, and the injection unit 07 injects molten resin into the second mold 04.

[0012] FIG. 2 is a schematic diagram showing a finished molded product 200 that can be molded using the manufacturing apparatus 100. The finished molded product 200 includes a first molded product 08, an elastic member 14, a second molded product 09, and a third molded product 12. The first molded product 08, the second molded product 09, and the third molded product 12 are connected (welded). Note that in the continuous manufacturing process performed by the manufacturing apparatus 100, two finished molded products with different shapes are manufactured, but each finished molded product is formed using three molded products and one elastic member. Therefore, in FIG. 2, for ease of explanation, the two finished molded products are shown to have the same shape, and multiple reference numerals are assigned to each component, such as the first molded products 08 and 10, the second molded products 09 and 11, and the third molded products 12 and 13. In FIG. 2, only one of the reference numerals (the first molded product 08, the second molded product 09, and the third molded product 12) will be used for explanation.

[0013] In the manufacturing process of the finished molded product 200, an elastic member 14 is inserted into a first molded product 08, and a second molded product 09 is assembled to the first molded product 08. Then, a third molded product 12 is assembled, and molten resin 15 is poured into the formed space by an injection unit 07 to join them. In this manner, the finished molded product 200 is formed. The molten resin 15 may be made of a material different from the materials of the first molded product 08, the second molded product 09, and the third molded product 12, or may be made of the same material.

[0014] Figure 3 is an image diagram showing how three parts are assembled inside a mold. Other parts are assembled to a first molded part 08 molded inside the mold. This diagram shows the assembly of other parts, an elastic member 14, a second molded part 09, and a third molded part 12, to the first molded part 08, which is molded between the first mold 03 and the intermediate mold 05 and held in the intermediate mold 05. The second molded part 09 and the third molded part 12 are parts molded in a molding process that precedes assembly. Figure 3 shows the second molded part 09 and the third molded part 12 being removed from the mold after molding and assembled to the first molded part 08.

[0015] Abutment and assembly require clearance, which is the unevenness of the parts to allow them to engage with each other, and this clearance includes a margin of error to ensure engagement. Therefore, the greater the number of parts, the greater the accumulation of error, increasing the risk of parts being misaligned or tilted by the clearance during assembly. As shown in Figure 3, tilting can occur particularly when the parts are removed from the mold after molding and then assembled. The parts are designed to fit into the cavity within the mold when the mold is closed. However, if the misalignment or tilt is too large, the molded parts may not fit into the cavity and may become pinched by the mold, resulting in molding defects. For this reason, in this embodiment, the second molded product 09 is removed from the mold and assembled to the first molded product 08, while the third molded product 12 is assembled to the first molded product 08 while still held in the second mold 04.

[0016] FIG. 4(a) is a top view showing the manufacturing apparatus 100 of this embodiment, and FIGS. 4(b) to 4(e) are schematic diagrams showing areas on each surface of the intermediate mold 05 corresponding to two types of molded finished products. As shown in FIG. 4(a), the intermediate mold 05 has four surfaces, surface A 41 to surface D 44, and rotates every 90 degrees. By rotating the intermediate mold 05 in this manner, the first mold 03 and the second mold 04 face surface A 41 (see FIG. 4(b)), surface B 42 (see FIG. 4(c)), surface C 43 (see FIG. 4(d)), and surface D 44 (see FIG. 4(e)) of the intermediate mold 05 in this order.

[0017] Surfaces A 41 to D 44 of the intermediate mold 05 have regions for molding two types of finished products. Surface A 41 has surface A first region 41a and surface A second region 41b, surface B 42 has surface B first region 42a and surface B second region 42b, surface C 43 has surface C first region 43a and surface C second region 43b, and surface D 44 has surface D first region 44a and surface D second region 44b. Furthermore, surface A first region 41a has upper region 21, and surface A second region 41b has upper region 16 and lower region 17. Surface B first region 42a has upper region 19 and lower region 18, and surface B second region 42b has lower region 20. The C-side first region 43a includes an upper region 21', the C-side second region 43b includes an upper region 16' and a lower region 17', the D-side first region 44a includes an upper region 19' and a lower region 18', and the D-side second region 44b includes a lower region 20'.

[0018] The intermediate mold 05 alternately molds parts for each model every 90 degrees, so that the A side 41 and the C side 43 have similar areas, and the B side 42 and the D side 44 have similar areas. Furthermore, pieces for molding molded products are placed in each area from the A side 41 to the D side 44. The pieces can mold not only one molded product, but multiple identical molded products, making it possible to accommodate multi-cavity molding for efficient product production.

[0019] Fig. 5(a) is a side view showing the manufacturing apparatus 100. Fig. 5(b) shows the first surface 50 of the first mold 03, Fig. 5(c) shows the second surface 51 of the second mold 04 when the piece is arranged at the bottom, and Fig. 5(d) shows the second surface 51 of the second mold 04 when the piece is arranged at the top.

[0020] The first surface 50 includes a first region 50a and a second region 50b, and the first region 50a includes an upper region 22 and a lower region 23. The second region 50b includes an upper region 25 and a lower region 24. The second surface 51 includes a first region 51a and a second region 51b, and includes a region 26 that moves up and down in the first region 51a and a region 27 that moves up and down in the second region 51b. Regions 26 and 27 move adjacent to each other.

[0021] An upper region 22 of the first region 50a on the first surface 50 corresponds to an upper region 16 of the surface A second region 41b on the surface A 41 of the intermediate mold 05 or an upper region 16' of the surface C second region 43b, and forms a first molded product 08. A lower region 23 of the first region 50a corresponds to a lower region 17 of the surface A second region 41b on the surface A 41 of the intermediate mold 05 or a lower region 17' of the surface C second region 43b, and forms a second molded product 09.

[0022] The upper region 25 of the second region 51b on the first surface 50 corresponds to the upper region 19 of the surface B first region 42a on the surface B 42 of the intermediate mold 05 or the upper region 19' of the surface D first region 44a, thereby forming the first molded product 10. The lower region 24 of the second region 51b corresponds to the lower region 18 of the surface B first region 42a on the surface B 42 of the intermediate mold 05 or the lower region 18' of the surface D first region 44a, thereby forming the second molded product 11.

[0023] The area 26 that moves in the first area 51a on the second surface 51 corresponds to the lower area 20 in the B surface second area 42b of the intermediate mold 05 or the lower area (part of the area) 20' in the D surface second area 44b, and forms the third molded product 12.

[0024] The region 27 moving in the second region 51b on the second surface 51 corresponds to the upper region 21 in the A-surface first region 41a or the upper region 21' in the C-surface first region 43a of the intermediate mold 05, and forms the third molded product 13.

[0025] 6(a) to 6(d) are diagrams showing the molding process in this embodiment. In this embodiment, two types of integrally molded products are molded alternately and repeatedly. The molding process in this embodiment will be explained below in order of steps. Note that since the molding processes are performed continuously and simultaneously, the explanation will be based on the processing of surface A 41 of the intermediate mold 05, and will refer to the other surfaces (surface B 42, surface C 43, and surface D 44).

[0026] In the first step shown in Figure 6(a), with the first mold 03 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 06. As a result, a first molded product 08 is molded between the upper region 22 of the first region 50a on the first surface 50 of the first mold 03 and the upper region 16 of the surface A 41 of the intermediate mold 05. Furthermore, a second molded product 09 is molded between the lower region 23 of the first region 50a and the lower region 17 of the surface A second region 41b on the surface A 41 of the intermediate mold 05. When the mold is opened after molding, the first molded product 08 and the second molded product 09 remain in the intermediate mold 05.

[0027] Here, the method for leaving the molded product in the intermediate mold 05 is to provide a draft angle on the outer periphery of the molded product so that it can be removed from the first mold 03 and left in the intermediate mold 05 when the molds are opened. Depending on the shape of the molded product and the mold configuration, it is also possible to leave the molded product on the side of the mold where you want it to remain by using an ejector pin to eject the molded product on the side opposite to the side you want it to remain when the molds are opened.

[0028] 6(b), after the intermediate mold 05 is rotated 90 degrees in the direction of the arrow α, the first assembly robot 29 inserts the elastic member 14 into the first molded product 08 molded in the upper region 16 of the A-side 41 of the intermediate mold 05. After the elastic member 14 is inserted, the second molded product 09 molded in the lower region 17 of the A-side 41 is removed from the intermediate mold 05 by the first assembly robot 29, and moved so as to come into contact with the first molded product 08 for assembly.

[0029] Furthermore, with the first mold 03 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 06. As a result, a first molded article 10 is molded on the B surface 42 between the lower region 24 of the second region 50b of the first mold 03 and the lower region 18 of the B surface 42 of the intermediate mold 05. Furthermore, a second molded article 11 is molded between the upper region 25 of the second region 50b on the first surface 50 of the first mold 03 and the upper region 19 of the B surface 42 of the intermediate mold 05. Here, as in the first step, when the mold is opened after molding, the first molded article 10 and the second molded article 11 remain in the intermediate mold 05.

[0030] Furthermore, with the first piece 28 positioned at the bottom on the second surface 51 of the second mold 04, the second mold 04 and the intermediate mold 05 are closed together, and molten resin is injected into the mold from the injection unit 07. As a result, the third molded product 12 is molded between the lower region 20' and the region 26 on the D surface 44 of the intermediate mold 05.

[0031] At this time, the third molded product 12 is left in the second mold 04 when the molds are opened. The method for leaving a molded product in the second mold 04 is the same as the method for leaving a molded product in the intermediate mold 05 described above. The first piece 28 changes its position in the vertical direction every time the intermediate mold 05 rotates 90°, changing the area corresponding to the intermediate mold 05.

[0032] In the third step shown in FIG. 6(c), the intermediate mold 05 rotates 90° in the direction of arrow α. The first piece 28 moves to the top of the second mold 04. As a result, the upper region 16 of the surface A of the intermediate mold 05, in which the first molded product 08 and the second molded product 09 are arranged, faces the region 26 of the second mold 04, in which the third molded product 12 is arranged. After rotation, the second mold 04 and the intermediate mold 05 are closed together, and molten resin is injected from the injection unit 07 to bond the first molded product 08, the second molded product 09, and the third molded product 12, thereby forming a first integrated molded product 31, which is the completed molded product. In addition, a third molded product 13 is formed between the region 27 located at the top of the second mold 04 and the upper region 21 of the surface A 41 of the intermediate mold 05.

[0033] On the B surface 42, the first assembly robot 29 is used to insert the elastic member 14 into the first molded product 10. After the elastic member 14 has been inserted, the second molded product 11 molded in the upper region 19 of the B surface 42 is removed from the intermediate mold 05 by the first assembly robot 29, and is moved so as to come into contact with the first molded product 10 and assembled thereto.

[0034] Furthermore, with the first mold 03 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 06. As a result, on the C surface 43, a first molded product 08 is molded between the upper region 22 of the first region 50a on the first surface 50 of the first mold 03 and the upper region 16' of the C surface 43 of the intermediate mold 05. Furthermore, a second molded product 09 is molded between the lower region 23 of the first region 50a and the lower region 17' of the C surface 43 of the intermediate mold 05. When the mold is opened after molding, the first molded product 08 and the second molded product 09 remain in the intermediate mold 05.

[0035] In the fourth step shown in FIG. 6(d), after the intermediate mold 05 is rotated by 90° in the direction of the arrow α, the first integrally molded product 31 is removed from the A surface 41 by using the second assembly robot 30.

[0036] With the second mold 04 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 07, whereby a third molded product 12 is molded on the B surface 42 between the region 26 that has moved to the bottom of the second mold 04 and the lower region 20 of the B surface 42 of the intermediate mold 05. Furthermore, the first molded product 10, the second molded product 11, and the third molded product 13 are joined between the lower region 18 in the first region 42a of the B surface of the intermediate mold 05 and the region 27 arranged at the bottom of the second mold 04, thereby forming a second integrated molded product 32, which is the completed molded product.

[0037] On the C surface 43, the first assembly robot 29 is used to insert the elastic member 14 into the first molded product 08 molded in the upper region 16 of the A surface 41 of the intermediate mold 05. After the elastic member 14 is inserted, the second molded product 09 molded in the lower region 17' of the C surface 43 is removed from the intermediate mold 05 by the first assembly robot 29, and moved so as to come into contact with the first molded product 08 and assemble it.

[0038] At the D-surface 44, with the first mold 03 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 06. As a result, a first molded article 10 is molded between the lower region 24 of the second region 50b in the first mold 03 and the lower region 18' of the D-surface 44 of the intermediate mold 05. Furthermore, a second molded article 11 is molded between the upper region 25 of the second region 50b in the first surface 50 of the first mold 03 and the upper region 19' of the D-surface 44 of the intermediate mold 05. Here too, when the mold is opened after molding, the first molded article 10 and the second molded article 11 remain in the intermediate mold 05.

[0039] By repeating this series of processes, two types of integrated molded products combining three parts can be molded alternately.

[0040] Fig. 7 is an image diagram showing the molded products (first integrally molded product 31 and second integrally molded product 32) molded in the third step of Fig. 6(c) and the fourth step of Fig. 6(d). Here, the third step will be described as an example.

[0041] In the third step, the assembled first molded product 08 and second molded product 09 are combined with a third molded product 12 to form a first integrally molded product 31. At this time, the third molded product 12 is not removed from the second mold 04, but is combined with the assembled first molded product 08 and second molded product 09 in the intermediate mold 05 to form the first integrally molded product 31. By not removing the third molded product 12 from the second mold 04, it is possible to assemble the molded products without tilting or misalignment.

[0042] 7, the second molded product 09 assembled to the first molded product 08 in the second step is removed from the mold used during molding and assembled using the first assembly robot 29, which may result in the second molded product 09 being assembled at an angle. However, by subsequently assembling the third molded product 12 without removing it from the second mold 04, the first integrated molded product 31 can be molded with the angle of the second molded product 09 corrected. In other words, according to this embodiment, misalignment and angle of parts in the clearance can be suppressed, and the yield of finished molded products can be improved, compared to the method described with reference to FIG. 3, in which the second molded product 09 and the third molded product 12 are removed from the mold in which they were molded and then assembled to the first molded product 08.

[0043] Figure 8 is a schematic diagram showing the first die 03, the intermediate die 05, and the second die 04 in the first step (see Figure 6(a)). Note that in Figure 8(a), the bridges are omitted.

[0044] In the first step, as described above, a first molded product 08 is molded using the injection unit 06 between the upper region 22 of the first region 50a on the first surface 50 of the first mold 03 and the upper region 16 of the surface A 41 of the intermediate mold 05. Furthermore, a second molded product 09 is molded using the injection unit 06 between the lower region 23 of the first region 50a and the lower region 17 of the surface A second region 41b on the surface A 41 of the intermediate mold 05.

[0045] At this time, the lower region 24 of the second region 50b of the first mold 03 and the upper region 25 of the second region 50b of the first mold 03 do not correspond to the pieces of the A-surface first region 41a (including the upper region 21) of the A-surface 41 of the intermediate mold 05 that face each other. More specifically, the second region 50b of the first mold 03 is a piece for molding the first molded product 10 and the second molded product 11 of the second integrally molded product 32. However, the opposing upper region 21 of the A-surface 41 of the intermediate mold 05 is a piece for molding the third molded product 13 of the second integrally molded product 32. Therefore, the pieces are configured not to interfere with each other when the mold is closed. Specifically, the pieces of the second region 50b of the first mold 03 protrude in the mold closing direction more than the pieces of the first region 50a. Furthermore, on the A surface 41 of the intermediate mold 05, the pieces in the second region 41b protrude further in the mold closing direction than the pieces in the first region 41a. When the A surface 41 of the intermediate mold 05 faces the first mold 03 and the two molds are closed, the pieces in the first region 50a of the first mold 03 and the pieces in the second region 41b of the intermediate mold 05 come into contact. However, the pieces in the second region 50b of the first mold 03 and the pieces in the first region 41a of the intermediate mold 05 (non-corresponding mold) are spaced apart. Details are explained below.

[0046] Figure 8(b) is a view showing the first die 03 and the intermediate die 05 when the die is opened as viewed from the arrow A, and Figure 8(c) is a view showing the first die 03 and the intermediate die 05 when the die is closed as viewed from the arrow A. In Figure 8(b), an upper link 82 and a lower link 83 in the first region 50a of the first die 03, and an upper link 84 and a lower link 85 in the second region 50b can be seen.

[0047] 8(c), when the molds are closed, the upper piece 82 in the first region 50a of the first mold 03 and the upper piece 80 in the second region 41b on the surface A of the intermediate mold 05 are combined to form a first molded product 08. Also, the lower piece 83 in the first region 50a of the first mold 03 and the lower piece 81 in the second region 41b on the surface A of the intermediate mold 05 are combined to form a second molded product 09.

[0048] Figure 8(d) is a view showing the first die 03 and the intermediate die 05 when the die is opened as viewed from the arrow B, and Figure 8(e) is a view showing the first die 03 and the intermediate die 05 when the die is closed as viewed from the arrow B. In Figure 8(d), an upper link 86 and a lower link 87 in the first region 41a on surface A of the intermediate die 05, and an upper link 80 and a lower link 81 in the second region 41b on surface A can be seen.

[0049] 8(e), when the molds are closed, the upper link 84 in the second region 50b of the first mold 03 and the upper link 86 in the first region 41a on the surface A of the intermediate mold 05 are not engaged with each other. Also, the lower link 85 in the second region 50b of the first mold 03 and the lower link 87 in the first region 41a on the surface A of the intermediate mold 05 are not engaged with each other.

[0050] Figure 9 is a schematic diagram showing the first die 03, the intermediate die 05, and the second die 04 in the second step (see Figure 6(b)). Note that in Figure 9(a), the bridges are omitted.

[0051] In the second step, as described above, the first molded article 10 is molded using the injection unit 06 between the lower region 24 of the second region 50b in the first mold 03 and the lower region 18 of the surface B 42 of the intermediate mold 05. Furthermore, the second molded article 11 is molded using the injection unit 06 between the upper region 25 of the second region 50b in the first surface 50 of the first mold 03 and the upper region 19 of the surface B 42 of the intermediate mold 05.

[0052] At this time, the lower region 23 of the first region 50a of the first mold 03 and the upper region 22 of the first region 50a of the first mold 03 do not correspond to the pieces of the surface B second region 42b (including the lower region 20) of the opposing surface B 42 of the intermediate mold 05. Therefore, the pieces are configured not to interfere with each other when the mold is closed. Specifically, as described above, the pieces of the second region 50b of the first mold 03 protrude in the mold closing direction more than the pieces of the first region 50a. Furthermore, on the surface B 42 of the intermediate mold 05, the pieces of the first region 42a protrude in the mold closing direction more than the pieces of the second region 41b. When the first mold 03 and the intermediate mold 05 are closed with their surface B 42 facing each other, the pieces of the second region 50b of the first mold 03 and the pieces of the first region 41a of the intermediate mold 05 abut against each other. However, the pieces in the first region 50a of the first die 03 are spaced apart from the pieces in the second region 41b of the intermediate die 05. Details will be explained below.

[0053] Figure 9(b) is a view showing the first die 03 and the intermediate die 05 when the die is opened as viewed from the arrow C, and Figure 9(c) is a view showing the first die 03 and the intermediate die 05 when the die is closed as viewed from the arrow C. In Figure 9(b), an upper link 82 and a lower link 83 in the first region 50a of the first die 03, and an upper link 84 and a lower link 85 in the second region 50b, can be seen. Also, an upper link 90 and a lower link 91 in the B-surface second region 42b of the B-surface 42 of the intermediate die 05, and an upper link 96 and a lower link 97 in the B-surface first region 42a can be seen.

[0054] As shown in Figure 9(c), when the molds are closed, the upper link 84 in the second region 50b of the first mold 03 and the upper link 96 in the surface B first region 42a of the intermediate mold 05 are mated to form the second molded product 11. Also, the lower link 85 in the second region 50b of the first mold 03 and the lower link 97 in the surface B first region 42a of the intermediate mold 05 are mated to form the first molded product 10. At this time, the upper link 82 in the first region 50a of the first mold 03 and the upper link 90 in the surface B second region 42b of the surface B 42 of the intermediate mold 05 are not mated. Also, the lower link 83 in the first region 50a of the first mold 03 and the lower link 91 in the surface B second region 42b of the surface B 42 of the intermediate mold 05 are not mated.

[0055] Figure 9(d) is a view showing the first die 03 and the intermediate die 05 when the die is opened as viewed from the arrow D, and Figure 9(e) is a view showing the first die 03 and the intermediate die 05 when the die is closed as viewed from the arrow D. In Figure 9(d), an upper link 96 and a lower link 97 in the first region 42a of surface B, and an upper link 84 and a lower link 85 in the second region 50b of the first die 03 can be seen.

[0056] As shown in Figure 9(e), when the mold is closed, an upper link 96 in the first region 42a of surface B and an upper link 84 in the second region 50b of the first mold 03 are combined. Also, a lower link 97 in the first region 42a of surface B and a lower link 85 in the second region 50b of the first mold 03 are combined. In this way, when non-corresponding links face each other, the positions of the mold surfaces in the mold opening / closing direction are appropriately shifted so that the links do not interfere with each other when the mold is closed.

[0057] In this way, the first mold 03 is divided into a first region 50a and a second region 50b, and each of the surfaces A to D of the intermediate mold 05 is divided into a first region and a second region. Furthermore, the second mold 04 is configured so that the piece can move between an upper position (first position) and a lower position (second position). This makes it possible to provide a molded product manufacturing method and manufacturing device that can perform more complex molding.

[0058] (Variation) A modification of the first embodiment of the present invention will now be described with reference to the drawings.

[0059] 10(a) to 10(d) are diagrams showing the molding process in a modified example. Unlike the first embodiment, which can repeatedly mold two types of integrally molded products alternately, this modified example involves repeatedly molding one type of integrally molded product. The molding process in this embodiment will be explained below in order of steps. Note that since the molding processes are performed continuously and simultaneously, the explanation will be based on the processing of surface A 41 of the intermediate mold 05, and will refer to the other surfaces (surface B 42, surface C 43, surface D 44).

[0060] 10(a), with the first mold 03 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 06. As a result, a first molded product 08 is molded between the upper region 22 of the first region 50a on the first surface 50 of the first mold 03 and the upper region 16 of the surface A 41 of the intermediate mold 05. Furthermore, a second molded product 09 is molded between the lower region 23 of the first region 50a and the lower region 17 of the surface A second region 41b on the surface A 41 of the intermediate mold 05. When the mold is opened after molding, the first molded product 08 and the second molded product 09 remain in the intermediate mold 05.

[0061] 10(b), after the intermediate mold 05 is rotated 90 degrees in the direction of the arrow α, the first assembly robot 29 inserts the elastic member 14 into the first molded product 08 molded in the upper region 16 of the A-side 41 of the intermediate mold 05. After the elastic member 14 is inserted, the second molded product 09 molded in the lower region 17 of the A-side 41 is removed from the intermediate mold 05 by the first assembly robot 29, and moved so as to come into contact with the first molded product 08 for assembly.

[0062] At the D surface 44, with the second mold 04 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 07. As a result, a third molded product 12′ is molded between the region 26 when the first piece 28 is positioned at the bottom on the second surface 51 of the second mold 04 and the lower region 20′ of the D surface 44 of the intermediate mold 05.

[0063] At this time, when the molds are opened, the third molded product 12' remains in the second mold 04. The first piece 28 changes its position in the vertical direction every time the intermediate mold 05 rotates by 90°, changing the area corresponding to the intermediate mold 05.

[0064] 10(c), the intermediate mold 05 is rotated by 90° in the direction of the arrow α. Then, with the second mold 04 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 07. As a result, the assembled first molded product 08 and second molded product 09 are combined with the third molded product 12′ in the upper region 16 of the second region 41b on surface A of the intermediate mold 05 and the region 26 when the first piece 28 is positioned at the top of the second mold 04, thereby forming a first integrally molded product 31.

[0065] At the C-face 43, with the first mold 03 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 06. As a result, a first molded product 08 is molded between the upper region 22 of the first region 50a on the first surface 50 of the first mold 03 and the upper region 16' of the C-face 43 of the intermediate mold 05. Furthermore, a second molded product 09 is molded between the lower region 23 of the first region 50a and the lower region 17' of the C-face 43 of the intermediate mold 05. When the mold is opened after molding, the first molded product 08 and the second molded product 09 remain in the intermediate mold 05.

[0066] In the fourth step shown in FIG. 10(d), after the intermediate mold 05 is rotated by 90° in the direction of the arrow α, the first integral molding 31 is removed from the A surface 41 by using the second assembly robot 30.

[0067] With the second mold 04 and the intermediate mold 05 closed, molten resin is injected into the mold from the injection unit 07. As a result, on the B surface 42, a third molded product 12' is formed between the region 26 when the first piece 28 is positioned at the bottom on the second surface 51 of the second mold 04 and the lower region 20 on the B surface 42 of the intermediate mold 05.

[0068] On the C surface 43, the first assembly robot 29 is used to insert the elastic member 14 into the first molded product 08 molded in the upper region 16 of the A surface 41 of the intermediate mold 05. After the elastic member 14 is inserted, the second molded product 09 molded in the lower region 17' of the C surface 43 is removed from the intermediate mold 05 by the first assembly robot 29, and moved so as to come into contact with the first molded product 08 and assemble it.

[0069] In this way, the method of this modified example allows for repeated molding of one type of integrally molded product.

[0070] (Other embodiments) In the first embodiment, the first integrally molded product 31 and the second integrally molded product 32 are respectively formed by molding and combining a first molded product, a second molded product, and a third molded product. However, the present invention is not limited to this. The first molded product and the second molded product may be molded and combined to form an integrally molded product without molding a third molded product. That is, the first integrally molded product 31 may include the first molded product 08 and the second molded product 09 but not the third molded product 12, and the second integrally molded product 31 may include the first molded product 10 and the second molded product 11 but not the third molded product 13.

[0071] The disclosure of this embodiment includes the following methods and configurations.

[0072] (Method 1) a first mold having a first surface; a second mold having a second surface; an intermediate mold having surfaces A, B, C, and D that can face the first surface and the second surface, and that can change the surfaces that face the first surface and the second surface by rotating between the first mold and the second mold; A method for manufacturing a molded product using the method, a first molding step of closing the first mold and the intermediate mold with the surface A facing the first surface and injecting molten resin into the molds to mold a first part and a second part between the first surface and the surface A; a second molding step of closing the first mold and the intermediate mold with the B surface facing the first surface, and injecting molten resin into the molds to mold a third part and a fourth part between the first surface and the B surface, while engaging the second part with the first part held on the A surface; a third molding step of closing the second mold and the intermediate mold with the A surface facing the second surface, and injecting molten resin into the mold to weld the first part and the second part to form a first integrally molded product, while engaging the fourth part with the third part held on the B surface; a fourth molding step of clamping the second mold and the intermediate mold together with the second surface facing the B surface, and injecting molten resin into the molds to weld the third part and the fourth part together, thereby molding a second integrally molded product that is different from the first integrally molded product; A method for manufacturing a molded product, comprising:

[0073] (Method 2) The pieces on said C side are the same type as the pieces on said A side, and the pieces on said D side are the same type as the pieces on said B side, in the second molding step, the second mold and the intermediate mold are closed together with the D surface facing the second surface, and a molten resin is injected into a mold formed by a first region of the second surface and a partial region of the D surface, thereby molding a fifth part between the second surface and the D surface; In the third molding step, the first mold and the intermediate mold are closed together with the C surface facing the first surface, and molten resin is injected into the molds to mold the first part and the second part between the first surface and the C surface; further, the second mold and the intermediate mold are closed together with the A surface holding the first part and the second part engaged in the second molding step facing the second surface that holds the fifth part molded in the second molding step, and molten resin is injected into the molds to weld the first part, the second part, and the fifth part together, thereby molding the first integrally molded product; In the fourth molding step, the first mold and the intermediate mold are closed together with the D surface facing the first surface, and molten resin is injected into the molds to mold the third part and the fourth part between the first surface and the D surface; The method for manufacturing a molded product according to Method 1, characterized in that in the fourth molding step, the first integrally molded product is removed from the intermediate mold.

[0074] (Method 3) A method for manufacturing a molded product described in Method 1 or 2, characterized in that, on the second surface, the first region and the second region adjacent to the first region are movable between a first position and a second position while being adjacent to each other.

[0075] (Method 4) The method for manufacturing a molded product described in Method 3, characterized in that the first area and the second area move as the intermediate mold rotates.

[0076] (Method 5) In the second forming step, the second part is engaged with the first part by a robot; A method for manufacturing a molded product described in any one of methods 1 to 4, wherein in the third molding step, the fourth part is engaged with the second part by a robot.

[0077] (Method 6) In the second molding step, the robot inserts a first member between the first part and the second part, A molded product manufacturing method described in Method 5, wherein in the third molding step, the robot inserts a second member between the third part and the fourth part.

[0078] (Method 7) The method for manufacturing a molded product described in Method 6, wherein the first member and the second member are elastic members.

[0079] (Method 8) the resin used to weld the first component and the second component in the third molding step is a resin made of a material different from that of the first component and the second component, A method for manufacturing a molded product described in any one of Methods 1 to 7, wherein the resin used to weld the third part and the fourth part together in the fourth molding step is a resin of a material different from that of the third part and the fourth part.

[0080] (Method 9) a first mold having a first surface; a second mold having a second surface; an intermediate mold having surfaces A, B, C, and D that can face the first surface and the second surface, and that can change the surfaces that face the first surface and the second surface by rotating between the first mold and the second mold, a first molding step of closing the first mold and the intermediate mold with the first surface facing the first mold and injecting molten resin into the molds to mold a first part and a second part between the first mold and the first surface; a second molding step of closing the second mold and the intermediate mold with the D surface facing the second surface, and injecting molten resin into the mold to mold a fifth component between the second surface and the D surface while engaging the second component with the first component held on the A surface; a third molding step of closing the second mold and the intermediate mold in a state where the surface A, which holds the first component and the second component engaged in the second molding step, faces the second surface, which holds the fifth component molded in the second molding step, and injecting molten resin into the molds to weld the first component, the second component, and the fifth component together to mold a first integrally molded product; A method for manufacturing a molded article comprising the steps of:

[0081] (Method 10) In the second molding step, the first mold and the intermediate mold are closed together with the surface B facing the first surface, and a molten resin is injected into the molds to mold a third part and a fourth part between the first surface and the surface B; In the third molding step, the first mold and the intermediate mold are closed together with the A surface facing the second surface, and a molten resin is injected into the molds to further mold a sixth part between the first surface and the A surface, while engaging the fourth part with the third part held on the B surface; a fourth molding step of closing the second mold and the intermediate mold in a state where the second surface that holds the sixth component molded in the third molding step is opposed to the surface B that holds the third component and the fourth component engaged in the third molding step, and injecting molten resin into the molds to weld the third component, the fourth component, and the sixth component together to mold a second integrally molded product different from the first integrally molded product, 10. The method for manufacturing a molded product according to method 9, wherein in the fourth molding step, the first integrally molded product is removed from the intermediate mold.

[0082] (Configuration 1) a first mold connected to a first injection unit that injects resin and having a first surface; a second mold connected to a second injection unit that injects resin and having a second surface; an intermediate mold provided between the first mold and the second mold and having four surfaces A, B, C, and D that can face the first surface and the second surface; A manufacturing apparatus comprising: The first surface and the surface A are provided with pieces that are opposed to each other when the mold is closed, and that can mold a first part and a second part by injecting molten resin from the first injection unit; pieces are arranged on the first surface and the B surface, and the pieces are closed together while facing each other, and are capable of molding a third part and a fourth part by injecting molten resin from the first injection unit; a piece is disposed on the second surface, the piece being opposed to the A surface when the mold is closed, and the piece is capable of welding the first part and the second part together to form a first integratedly molded product when molten resin is injected from the second injection unit; A piece is arranged on the second surface, which is closed in a state facing the B surface, and which can weld the third part and the fourth part together by injecting molten resin from the second injection unit to form a second integrally molded product different from the first integrally molded product. A manufacturing apparatus characterized by:

[0083] (Configuration 2) a first mold connected to a first injection unit that injects resin and having a first surface; a second mold connected to a second injection unit that injects resin and having a second surface; an intermediate mold provided between the first mold and the second mold and having four surfaces A, B, C, and D that can face the first surface and the second surface; A manufacturing apparatus comprising: The first surface and the A surface are provided with pieces that can be molded into a first part and a second part by closing the mold while facing each other and injecting molten resin into the mold, The second surface and the D surface are provided with pieces that can mold a fifth part by closing the mold while facing each other and injecting molten resin into the mold, The second surface and the surface A that hold the fifth component are provided with pieces that can mold a first integrally molded product by closing the mold with the surface A that holds the engaged first component and the second component facing each other and injecting molten resin into the mold. A manufacturing apparatus characterized by:

[0084] (Configuration 3) a mold that is closed and molds the first part and the second part when the first surface and the A surface are closed in a state where they face each other; The manufacturing apparatus according to configuration 2 is characterized in that it is provided with a non-compatible mold that is not clamped and is spaced apart. [Explanation of symbols]

[0085] 03 First Type 04 Second Type 05 Intermediate type 06 Injection unit 07 Injection unit 08 First molded product 09 Secondary molded product 10 First molded article 11 Secondary articles 14 Elastic member

Claims

1. a first mold having a first surface; a second mold having a second surface; an intermediate mold having surfaces A, B, C, and D that can face the first surface and the second surface, and that can change the surfaces that face the first surface and the second surface by rotating between the first mold and the second mold; A method for manufacturing a molded product using the method, a first molding step of closing the first mold and the intermediate mold with the A-side facing the first side and injecting molten resin into the molds to mold a first part and a second part between the first side and the A-side; a second molding step of closing the first mold and the intermediate mold with the B surface facing the first surface, and injecting molten resin into the mold to mold a third part and a fourth part between the first surface and the B surface, while engaging the second part with the first part held on the A surface; a third molding step of closing the second mold and the intermediate mold with the A surface facing the second surface, and injecting molten resin into the mold to weld the first part and the second part to form a first integrally molded product, while engaging the fourth part with the third part held on the B surface; a fourth molding step of clamping the second mold and the intermediate mold together with the second surface facing the B surface, and injecting molten resin into the molds to weld the third part and the fourth part together, thereby molding a second integrally molded product that is different from the first integrally molded product; A method for manufacturing a molded product, comprising:

2. The pieces on said C side are the same type as the pieces on said A side, and the pieces on said D side are the same type as the pieces on said B side, In the second molding step, the second mold and the intermediate mold are closed together with the D surface facing the second surface, and a molten resin is injected into a mold formed by a first region of the second surface and a partial region of the D surface, thereby molding a fifth part between the second surface and the D surface; In the third molding step, the first mold and the intermediate mold are closed together with the C surface facing the first surface, and molten resin is injected into the molds to mold the first part and the second part between the first surface and the C surface; further, the second mold and the intermediate mold are closed together with the A surface holding the first part and the second part engaged in the second molding step facing the second surface that holds the fifth part molded in the second molding step, and molten resin is injected into the molds to weld the first part, the second part, and the fifth part together, thereby molding the first integrally molded product; In the fourth molding step, the first mold and the intermediate mold are closed together with the D surface facing the first surface, and molten resin is injected into the molds to mold the third part and the fourth part between the first surface and the D surface; 2. The method for manufacturing a molded product according to claim 1, wherein in the fourth molding step, the first integrally molded product is removed from the intermediate mold.

3. 3. The method for manufacturing a molded product according to claim 2, wherein, on the second surface, the first region and the second region adjacent to the first region are movable between a first position and a second position while being adjacent to each other.

4. 4. The method for manufacturing a molded product according to claim 3, wherein the first region and the second region move in accordance with the rotation of the intermediate mold.

5. In the second forming step, the second part is engaged with the first part by a robot; 2. The method for manufacturing a molded product according to claim 1, wherein in the third molding step, the fourth part is engaged with the second part by a robot.

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

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

8. the resin used to weld the first component and the second component in the third molding step is a resin made of a material different from that of the first component and the second component, 2. The method for manufacturing a molded product according to claim 1, wherein the resin used to weld the third part and the fourth part together in the fourth molding step is a resin made of a material different from that of the third part and the fourth part.

9. a first mold having a first surface; a second mold having a second surface; an intermediate mold having surfaces A, B, C, and D that can face the first surface and the second surface, and that can change the surfaces that face the first surface and the second surface by rotating between the first mold and the second mold, a first molding step of closing the first mold and the intermediate mold with the first surface facing the first mold and injecting molten resin into the molds to mold a first part and a second part between the first mold and the first surface; a second molding step of closing the second mold and the intermediate mold with the D surface facing the second surface, and injecting molten resin into the mold to mold a fifth component between the second surface and the D surface, while engaging the second component with the first component held on the A surface; a third molding step of closing the second mold and the intermediate mold in a state where the surface A, which holds the first component and the second component engaged in the second molding step, faces the second surface, which holds the fifth component molded in the second molding step, and injecting molten resin into the molds to weld the first component, the second component, and the fifth component together to mold a first integrally molded product; A method for manufacturing a molded article comprising the steps of:

10. In the second molding step, the first mold and the intermediate mold are closed together with the surface B facing the first surface, and a molten resin is injected into the molds to mold a third part and a fourth part between the first surface and the surface B; In the third molding step, the first mold and the intermediate mold are closed together with the A surface facing the second surface, and a molten resin is injected into the molds to further mold a sixth part between the first surface and the A surface, while engaging the fourth part with the third part held on the B surface; a fourth molding step of closing the second mold and the intermediate mold in a state where the second surface that holds the sixth component molded in the third molding step is opposed to the surface B that holds the third component and the fourth component engaged in the third molding step, and injecting molten resin into the molds to weld the third component, the fourth component, and the sixth component together to mold a second integrally molded product different from the first integrally molded product, The method for manufacturing a molded product according to claim 9, wherein in the fourth molding step, the first integrally molded product is removed from the intermediate mold.

11. a first mold connected to a first injection unit that injects resin and having a first surface; a second mold connected to a second injection unit that injects resin and having a second surface; an intermediate mold provided between the first mold and the second mold, the intermediate mold having four surfaces A, B, C, and D that can face the first surface and the second surface; A manufacturing apparatus comprising: pieces are arranged on the first surface and the surface A, and the pieces are closed together while facing each other, and are capable of molding a first part and a second part by injecting molten resin from the first injection unit; pieces are arranged on the first surface and the B surface, and the pieces are closed together while facing each other, and are capable of molding a third part and a fourth part by injecting molten resin from the first injection unit; a piece is disposed on the second surface, the piece being opposed to the A surface when the mold is closed, and the piece is capable of welding the first component and the second component together to form a first integrally molded product when molten resin is injected from the second injection unit; A piece is arranged on the second surface, which is closed in a state facing the B surface, and which can weld the third part and the fourth part together by injecting molten resin from the second injection unit to form a second integrally molded product different from the first integrally molded product. A manufacturing apparatus characterized by:

12. a first mold connected to a first injection unit that injects resin and having a first surface; a second mold connected to a second injection unit that injects resin and having a second surface; an intermediate mold provided between the first mold and the second mold, the intermediate mold having four surfaces A, B, C, and D that can face the first surface and the second surface; A manufacturing apparatus comprising: The first surface and the A surface are provided with pieces that can be molded into a first part and a second part by closing the mold while facing each other and injecting molten resin into the mold, a piece is disposed on the second surface and the D surface, the piece being capable of molding a fifth part by closing the mold in a state where the piece is opposed to each other and injecting molten resin into the mold; The second surface and the surface A that hold the fifth component are provided with pieces that can mold a first integrally molded product by closing the mold in a state where the surface A that holds the engaged first component and the second component and the second surface face each other, and injecting molten resin into the mold. A manufacturing apparatus characterized by:

13. a mold closed on the first surface and the surface A, which molds the first part and the second part when the molds are closed in a state where the first surface and the surface A are opposed to each other; 13. The manufacturing apparatus according to claim 12, further comprising: a non-matching mold that is spaced apart and not clamped.

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