Method for manufacturing resin molded product and assembly

Abstract

To easily separate a plurality of components connected to a runner part from the runner part without reducing resin injectability during molding.SOLUTION: A resin molded product includes: a plurality of components; a plurality of gate parts formed in connection with the plurality of components; and a runner part formed in connection with the plurality of gate parts. The plurality of components are configured to be separated and assembled in one direction from the plurality of gate parts and the runner part, and the gate part has a step part having a step in the one direction and extends along a direction intersecting the one direction.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a resin molded product and an assembly. [Background technology]

[0002] An automatic assembly device automatically assembles parts by using an automatic part alignment device to supply parts for assembly. The automatic part alignment device aligns multiple parts of one type, such as parts placed in a bowl, so that each part faces the same direction and supplies them to the automatic assembly device. When using an automatic assembly device that assembles multiple types of parts in a single process, an automatic part alignment device is required for each type of part, increasing the cost and space required for assembling the parts. For example, Patent Document 1 discloses a technology in which a resin molded product having multiple parts connected to runners is supplied to an automatic assembly device, and the multiple parts are separated from the runners using a cutting tool such as a cutter for assembly. The multiple parts connected to the runners are integrally molded so that they are assembled in one direction. By assembling the multiple parts separated from the runners in the same orientation as when they were separated, multiple parts can be easily assembled automatically. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-83657 Summary of the Invention [Problem to be solved by the invention]

[0004] To improve safety and maintainability, it is desirable to separate parts from runners without using cutting tools such as cutters. One method for separating parts from runners is to grip the parts with fingers attached to a robot arm and tear them off from the runner. To reduce the gripping force required by the fingers to separate the parts from the runner, it is desirable to reduce the cross-sectional area of the gate connecting the runner and the part so that it breaks easily. However, reducing the cross-sectional area of the gate reduces resin injectability during molding.

[0005] An object of the present disclosure is to easily separate multiple parts connected to a runner portion from the runner portion without reducing resin injectability during molding. [Means for solving the problem]

[0006] A resin molded product according to one aspect of the present disclosure is a resin molded product having a plurality of parts, a plurality of gate portions formed and connected to the plurality of parts, and a runner portion formed and connected to the plurality of gate portions, wherein the plurality of parts are configured to be separated and assembled in one direction from the plurality of gate portions and the runner portion, and the gate portion has a step portion having a step in the one direction and extends along a direction intersecting the one direction. [Effects of the Invention]

[0007] According to the present disclosure, multiple components connected to a runner portion can be easily separated from the runner portion without reducing resin injectability during molding. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. [Figure 2] FIG. 10 is an enlarged view of the second part and the gate portion. [Figure 3] FIG. [Figure 4] FIG. 2 is a perspective view of a resin molded product and a finger. [Figure 5] FIG. 4 is a side cross-sectional view of a resin molded product and a finger. [Figure 6] 10A and 10B are explanatory views showing a process of separating the second part from the gate portion and the runner portion. [Figure 7] FIG. [Figure 8] FIG. 2 is a side cross-sectional view of the resin molded product and the parts stand. [Figure 9] FIG. [Figure 10] FIG. 10 is an enlarged view of the second part and the gate portion. [Figure 11] 10A and 10B are explanatory views showing a process of separating the second part from the gate portion and the runner portion. DETAILED DESCRIPTION OF THE INVENTION

[0009] Preferred embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. Note that the following embodiments do not limit the scope of the present disclosure, and not all combinations of features described in the following embodiments are necessarily essential to the solutions of the present disclosure. Note that the same components will be described with the same reference numerals.

[0010] <<First Embodiment>> <Configuration of resin molded products> FIG. 1 is an external view of a resin molded product 1 according to a first embodiment. FIG. 1(a) is a plan view of the resin molded product 1. FIG. 1(b) is a perspective view of the resin molded product 1. As shown in FIGS. 1(a) and 1(b), the resin molded product 1 according to the first embodiment has a spool portion 2, a runner portion 3, multiple gate portions 4, a first component 5, a second component 6A, a third component 6B, and a fourth component 7. The resin molded product 1 is produced by injection molding using a resin material. In this embodiment, a configuration will be described in which multiple components connected to the runner portion 3 can be easily separated from the runner portion 3 without reducing resin injectability during molding.

[0011] The spool portion 2 is formed in the center of the resin molded product 1, extending in the Z direction. The spool portion 2 is formed by resin flowing into a spool (not shown) in the mold for the resin molded product 1. The spool serves as an injection port through which molten resin is poured into the mold for the resin molded product 1.

[0012] The runner portion 3 is formed in the shape of a rectangular frame that is connected to the spool portion 2 and extends in the X and Y directions. The runner portion 3 is formed by resin that flows into a runner (not shown) of the mold for the resin molded product 1. The runner is a flow path that supplies the resin flowing in from the spool through a gate (not shown) to the first part 5, second part 6A, third part 6B, and fourth part 7 that are molded by the mold.

[0013] The gate portions 4 are formed by resin flowing into gates (not shown) of the mold for the resin molded product 1. Four gate portions 4 connected to a first component 5 are formed by connecting the first component 5 to the runner portion 3. Two gate portions 4 connected to a second component 6A are formed by connecting the second component 6A to the runner portion 3. Two gate portions 4 connected to a third component 6B are formed by connecting the third component 6B to the runner portion 3. Four gate portions 4 connected to a fourth component 7 are formed by connecting the fourth component 7 to the runner portion 3. As a result, the first component 5, the second component 6A, the third component 6B, and the fourth component 7 are connected to the runner portion 3 via the multiple gate portions 4 in the same orientation (posture) as when assembled by an automated assembly device (not shown).

[0014] FIG. 2 is an enlarged view of the second component 6A and the gate portion 4. FIG. 2(a) is an enlarged plan view of the second component 6A and the gate portion 4. FIG. 2(b) is an enlarged side view of the second component 6A and the gate portion 4. As shown in FIGS. 2(a) and 2(b), the gate portion 4 is formed to extend in a direction intersecting the Z direction, specifically, along the Y direction perpendicular to the Z direction. The two gate portions 4 are disposed symmetrically with respect to the second component 6A and are formed to be connected to both sides of the second component 6A in the Y direction.

[0015] A stepped portion 41 having a step in the Z direction is formed in the middle of the gate portion 4. The stepped portion 41 extends in a direction (YZ direction) inclined relative to the Z direction. In other words, the stepped portion 41 extends at an angle like an escalator in the middle of the gate portion 4. The cross-sectional area of the tip end of the gate portion 4 decreases as it approaches the second component 6A. The cross-sectional area of the tip end 42 of the gate portion 4 connected to the second component 6A is smaller than the cross-sectional area of the portion of the gate portion 4 excluding the tip end 42. The tip end 42 of the gate portion 4 is connected to the side surface of the end of the second component 6A on the -Z direction side. Because the gate portion 4 has such a shape, when the second component 6A is torn off from the gate portion 4 and the runner portion 3, the tip end 42 of the gate portion 4 breaks preferentially over other portions of the gate portion 4. When the tip 42 of the gate portion 4 breaks, the second part 6A is separated from the gate portion 4 and the runner portion 3 in the +Z direction (one direction) perpendicular to the plane (XY plane) including the frame-shaped runner portion 3.

[0016] The four gate portions 4 connected to the first component 5 are formed in the same manner as the two gate portions 4 connected to the second component 6A, and therefore detailed description thereof will be omitted. The four gate portions 4 are arranged two by two symmetrically with respect to the first component 5, and are formed connected to both sides of the first component 5 in the Y direction. Tip portions 42 of the gate portions 4 are connected to the side surface of the end portion of the first component 5 on the -Z direction side.

[0017] The two gates 4 connected to the third component 6B are formed in the same manner as the two gates 4 connected to the second component 6A, and therefore a detailed description thereof will be omitted. The two gates 4 are disposed symmetrically with respect to the third component 6B and are formed to be connected to both sides of the third component 6B in the Y direction. Tips 42 of the gates 4 are connected to the side surface of the end of the third component 6B on the -Z direction side.

[0018] The four gate portions 4 connected to the fourth component 7 are formed in the same manner as the two gate portions 4 connected to the second component 6A, and therefore detailed description thereof will be omitted. The four gate portions 4 are arranged two by two symmetrically with respect to the fourth component 7, and are formed connected to both sides of the fourth component 7 in the Y direction. Tip portions 42 of the gate portions 4 are connected to the side surface of the end portion of the fourth component 7 on the +Z direction side.

[0019] FIG. 3 is an external view of assembly 10. FIG. 3(a) is an exploded perspective view of assembly 10. FIG. 3(b) is a perspective view of assembly 10. As shown in FIGS. 3(a) and 3(b), assembly 10 can be produced by assembling a first part 5, a second part 6A, a third part 6B, and a fourth part 7 that have been separated from gate 4 and runner 3 in the +Z direction (one direction). In other words, assembly 10 can be produced by assembling first part 5, second part 6A, third part 6B, and fourth part 7 together while maintaining the orientation (posture) of the first part 5, second part 6A, third part 6B, and fourth part 7 when they were separated from gate 4 and runner 3. Note that first part 5, second part 6A, third part 6B, and fourth part 7 are automatically assembled using an automated assembly device (not shown). As described above, the first part 5, the second part 6A, the third part 6B, and the fourth part 7 of the resin molded product 1 are integrally molded in the same orientation (posture) as when assembled by an automatic assembly machine.

[0020] As shown in FIG. 3(a), the first component 5 is formed in the shape of a shaft extending in the Z direction. The first component 5 has a shaft-side base portion 51, a first shaft portion 52A, a second shaft portion 52B, and an engagement hole portion 53. The shaft-side base portion 51 is formed in the shape of a plate whose longitudinal direction extends in the X direction. The first shaft portion 52A is formed in the shape of a shaft that protrudes in the +Z direction from a portion of the shaft-side base portion 51 on the -X direction side. The second shaft portion 52B is formed in the shape of a shaft that protrudes in the +Z direction from a portion of the shaft-side base portion 51 on the +X direction side. The engagement hole portion 53 is formed in the shape of a square hole in the center of the shaft-side base portion 51.

[0021] The second part 6A is formed in a cylindrical shape extending in the Z direction. The second part 6A is assembled to the first shaft portion 52A of the first part 5 in the same orientation (posture) as when it was separated from the gate portion 4 and the runner portion 3. The third part 6B is formed in the same manner as the second part 6A. The third part 6B is assembled to the second shaft portion 52B of the first part 5 in the same orientation as when it was separated from the gate portion 4 and the runner portion 3. Note that the third part 6B may be assembled to the first shaft portion 52A, and the second part 6A may be assembled to the second shaft portion 52B.

[0022] The fourth component 7 is formed in a block shape extending in the Z direction. The fourth component 7 has a hole-side base portion 71, a first shaft hole portion 72A, a second shaft hole portion 72B, a support portion 73, and an engagement protrusion portion 74. The hole-side base portion 71 is formed in a plate shape with its longitudinal direction extending in the X direction. The first shaft hole portion 72A is formed in a circular hole shape on the −X direction side of the hole-side base portion 71 so as to be engageable with the first shaft portion 52A of the first component 5. The second shaft hole portion 72B is formed in a circular hole shape on the +X direction side of the hole-side base portion 71 so as to be engageable with the second shaft portion 52B of the first component 5. The support portion 73 is formed in a column shape protruding in the −Z direction from the center of the hole-side base portion 71. The engagement protrusion 74 is formed in a protrusion shape on the tip of the support portion 73 so as to be engageable with the engagement hole portion 53 of the first component 5. With the first shaft hole portion 72A and the second shaft hole portion 72B engaged with the first shaft portion 52A and the second shaft portion 52B, and the engaging protrusion portion 74 engaged with the engaging hole portion 53, the fourth part 7 is assembled to the first part 5 in the same orientation as when it was separated from the runner portion 3.

[0023] FIG. 4 is a perspective view of the resin molded product 1 and the fingers 12. FIG. 4(a) is a perspective view showing a state in which the second part 6A of the resin molded product 1 is gripped by the fingers 12. FIG. 4(b) is a perspective view showing a state in which the second part 6A gripped by the fingers 12 has been separated from the gate section 4 and the runner section 3. The fingers 12 are attached to a gripper 11 provided at the tip of a robot arm (not shown) of an automatic assembly device. As shown in FIGS. 4(a) and 4(b), the fingers 12 of the robot arm grip the second part 6A and pull it in the +Z direction (one direction), thereby tearing the second part 6A from the gate section 4 and the runner section 3. The fingers 12 of the robot arm grip the first part 5 and pull it in the +Z direction, thereby tearing the first part 5 from the gate section 4 and the runner section 3. Fingers 12 of the robot arm grasp third part 6B and pull it in the +Z direction, thereby separating third part 6B as if tearing it off from gate portion 4 and runner portion 3. Fingers 12 of the robot arm grasp fourth part 7 and pull it in the +Z direction, thereby separating fourth part 7 as if tearing it off from gate portion 4 and runner portion 3.

[0024] 4, for ease of understanding, the fingers 12 of the robot arm first separate the second component 6A from the gate portion 4 and the runner portion 3, but this is not limiting. It is preferable that the fingers 12 of the robot arm separate and assemble the first component 5, the second component 6A, the third component 6B, and the fourth component 7 in this order from the gate portion 4 and the runner portion 3. Alternatively, the fingers 12 of the robot arm may separate and assemble the first component 5, the third component 6B, the second component 6A, and the fourth component 7 in this order from the gate portion 4 and the runner portion 3.

[0025] FIG. 5 is a side cross-sectional view of the resin molded product 1 and the finger 12. As shown in FIG. 5, when each component of the resin molded product 1 is separated from the gate portion 4 and the runner portion 3, the holding member 13 presses and holds the runner portion 3 supported by the runner stool 14 in the -Z direction. The holding member 13 and the runner stool 14 are provided in an automated assembly device (not shown). For example, the holding member 13 presses and holds multiple locations of the runner portion 3 near the gate portion 4 in the -Z direction. As a result, for example, when the finger 12 of the robot arm moves the second component 6A in the +Z direction to tear it off from the gate portion 4 and the runner portion 3, the gate portion 4 elastically deforms and flexes, causing the tip portion 42 of the gate portion 4 to break.

[0026] <Manufacturing method for assembly> Next, a manufacturing method of the assembly 10 according to the first embodiment will be described briefly. First, the resin molded product 1 according to the first embodiment is manufactured by injection molding using an injection molding device (not shown). In the process of manufacturing the resin molded product 1, a step portion 41 having a step in the +Z direction (one direction) is formed in the middle of the gate portion 4 extending along the Y direction.

[0027] Next, a transfer robot (not shown) is used to transfer the resin molded article 1 produced using the injection molding device to a runner table 14 provided in an automatic assembly device (not shown). At this time, the runner portion 3 of the resin molded article 1 is supported by the runner table 14. Also at this time, a holding member 13 provided in the automatic assembly device presses and holds the runner portion 3 supported on the runner table 14 in the -Z direction. Note that instead of the transfer robot, a robot arm (not shown) provided in the automatic assembly device may be used to transfer the resin molded article 1 to the runner table 14.

[0028] Next, fingers 12 of a robot arm provided on the automatic assembly device grasp first component 5 and pull it in the +Z direction, thereby tearing and separating first component 5 from gate section 4 and runner section 3. Furthermore, fingers 12 of the robot arm place first component 5, which has been separated from gate section 4 and runner section 3, on an assembly jig (not shown) provided on the automatic assembly device while maintaining the orientation (posture) of first component 5 at the time of separation.

[0029] Next, fingers 12 of the robot arm grasp second part 6A and pull it in the +Z direction, thereby separating second part 6A by tearing it off from gate portion 4 and runner portion 3. Furthermore, fingers 12 of the robot arm assemble second part 6A separated from gate portion 4 and runner portion 3 onto first shaft portion 52A of first part 5 placed on the assembly jig, while maintaining the orientation of second part 6A at the time of separation.

[0030] Next, fingers 12 of the robot arm grasp third part 6B and pull it in the +Z direction, thereby tearing it off and separating third part 6B from gate portion 4 and runner portion 3. Furthermore, fingers 12 of the robot arm assemble third part 6B separated from gate portion 4 and runner portion 3 onto second shaft portion 52B of first part 5 placed on the assembly jig, while maintaining the orientation of third part 6B at the time of separation.

[0031] Next, fingers 12 of the robot arm grasp fourth part 7 and pull it in the +Z direction, thereby tearing it off and separating it from gate portion 4 and runner portion 3. Then, fingers 12 of the robot arm assemble fourth part 7, which faces the Z direction and has been separated from gate portion 4 and runner portion 3, to first part 5 placed on the assembly jig, while maintaining the orientation of fourth part 7 at the time of separation. As described above, fourth part 7 is assembled to first part 5 in a state in which first shaft hole portion 72A and second shaft hole portion 72B are engaged with first shaft portion 52A and second shaft portion 52B, and engagement protrusion portion 74 is engaged with engagement hole portion 53.

[0032] In this manner, assembly 10 can be produced by assembling first part 5, second part 6A, third part 6B, and fourth part 7, which are separated from gate 4 and runner 3 in the +Z direction (one direction). Furthermore, assembly 10 can be easily produced by performing only relative translation of the multiple parts constituting assembly 10 from molding to assembly, without rotational movement of each part about the X axis and the Y axis. One feature of this embodiment is that the direction of the step of step 41 formed in gate 4 and the direction in which each part of resin molded product 1 separates from gate 4 and runner 3 are aligned in the +Z direction (one direction). The +Z direction vector indicating the direction of the step of step 41 and the +Z direction vector indicating the direction in which each part of resin molded product 1 separates from gate 4 and runner 3 are parallel to each other.

[0033] FIG. 6 is an explanatory diagram showing the process of separating the second component 6A from the gate portion 4 and the runner portion 3. FIG. 6(a) is an explanatory diagram showing the state before the second component 6A is separated from the gate portion 4 and the runner portion 3. FIG. 6(b) is an explanatory diagram showing the state during the separation of the second component 6A from the gate portion 4 and the runner portion 3. FIG. 6(c) is an explanatory diagram showing the state after the second component 6A has been separated from the gate portion 4 and the runner portion 3. As shown in FIGS. 6(a) and 6(b), when the fingers 12 (not shown in FIG. 6) of the robot arm grasp the second component 6A and pull it in the +Z direction, the second component 6A moves relative to the runner portion 3 in the +Z direction. At this time, the gate portion 4 elastically deforms, causing the highest stress concentration to occur at the tip 42 of the gate portion 4. When the stress generated at the tip 42 of the gate portion 4 reaches the breaking stress of the resin (the material of the resin molded product 1), the tip 42 of the gate portion 4 breaks, and the second part 6A is torn off from the gate portion 4 and the runner portion 3, as shown in Figure 6(c).

[0034] In this embodiment, the gate portion 4 has a step portion 41 with a step in the +Z direction (one direction) and extends along the Y direction perpendicular to the +Z direction. When the fingers 12 of the robot arm tear off the second component 6A from the gate portion 4 and the runner portion 3, the gate portion 4 is easily elastically deformed, so that the elastic force of the gate portion 4 can be used to easily break the tip portion 42 of the gate portion 4. Therefore, the gripping force of the fingers 12 required to separate the second component 6A from the gate portion 4 and the runner portion 3 can be reduced without reducing the cross-sectional area of the gate portion 4. This allows the second component 6A connected to the runner portion 3 to be easily separated from the runner portion 3 without reducing resin injectability during molding. Furthermore, the gate portion 4 connected to the first component 5, the gate portion 4 connected to the third component 6B, and the gate portion 4 connected to the fourth component 7 are formed in the same manner as the gate portion 4 connected to the second component 6A. Therefore, the first component 5, the third component 6B, and the fourth component 7 connected to the runner portion 3 can be easily separated from the runner portion 3 without reducing the resin injectability during molding.

[0035] As described above, the manufacturing method of the resin molded product 1 and the assembly 10 according to the first embodiment allows multiple components connected to the runner portion 3 to be easily separated from the runner portion 3 without reducing resin injectability during molding. That is, in this embodiment, the gate portion 4 has a step portion 41 with a step in the +Z direction (one direction) and extends along the Y direction perpendicular to the +Z direction. When the fingers 12 of the robot arm tear off the second component 6A from the gate portion 4 and the runner portion 3, the gate portion 4 is easily elastically deformed, allowing the tip portion 42 of the gate portion 4 to be easily broken using the elastic force of the gate portion 4. Therefore, the gripping force of the fingers 12 required to separate the second component 6A from the gate portion 4 and the runner portion 3 can be reduced without reducing the cross-sectional area of the gate portion 4. This allows the second component 6A connected to the runner portion 3 to be easily separated from the runner portion 3 without reducing resin injectability during molding. Furthermore, similar to the second part 6A, the first part 5, the third part 6B, and the fourth part 7 connected to the runner part 3 can be easily separated from the runner part 3 without reducing the resin injectability during molding. In this way, multiple parts connected to the runner part 3 can be easily separated from the runner part 3 without reducing the resin injectability during molding.

[0036] Furthermore, the cross-sectional area of the tip 42 of the gate portion 4 is smaller than the cross-sectional area of the portion of the gate portion 4 excluding the tip 42. The tip 42 of the gate portion 4 is connected to the side surface of the end portion in the Z direction of each component in the resin molded product 1. This allows the tip 42 of the gate portion 4 to be broken preferentially over other portions of the gate portion 4 when separating multiple components connected to the runner portion 3 from the runner portion 3.

[0037] <<Second embodiment>> Next, a second embodiment will be described. Since the individual components in the second embodiment have the same configuration as those in the first embodiment, they will be described using the same reference numerals as those in the first embodiment.

[0038] <Configuration of resin molded products> FIG. 7 is a perspective view of a resin molded product 1 and a component stand 15 according to the second embodiment. FIG. 7(a) is a perspective view showing the resin molded product 1 placed on the component stand 15. FIG. 7(b) is a perspective view showing the components separated from the gate portion 4 and the runner portion 3 supported on the component stand 15. As shown in FIGS. 7(a) and 7(a), the resin molded product 1 according to the second embodiment is formed in the same manner as the resin molded product 1 according to the first embodiment. When the resin molded product 1 is placed on the component stand 15, the component stand 15 individually supports the first component 5, the second component 6A, the third component 6B, and the fourth component 7.

[0039] FIG. 8 is a side cross-sectional view of a resin molded product 1 and a component stand 15 according to the second embodiment. As shown in FIG. 8 and FIG. 7(a), the first component 5, the second component 6A, the third component 6B, and the fourth component 7 are supported on the component stand 15, while the runner portion 3 and the gate portion 4 are not supported on the component stand 15. When separating each component of the resin molded product 1 from the gate portion 4 and the runner portion 3, the pushing member 16 pushes the runner portion 3 that is not supported on the component stand 15 in the −Z direction. The component stand 15 and the pushing member 16 are provided in an automated assembly machine (not shown). For example, the pushing member 16 pushes multiple locations on the runner portion 3 near the gate portion 4 in the −Z direction. As a result, each component of the resin molded product 1 supported on the component stand 15 moves relative to the runner portion 3 in the +Z direction, causing the gate portion 4 connected to each component to elastically deform and flex, resulting in the breakage of the tip portion 42 of the gate portion 4. Therefore, by pushing the runner portion 3 in the -Z direction, the pushing member 16 can separate the first part 5, the second part 6A, the third part 6B, and the fourth part 7 all at once in the +Z direction (one direction) from the gate portion 4 and the runner portion 3.

[0040] <Manufacturing method for assembly> Next, a manufacturing method of the assembly 10 according to the second embodiment will be described briefly. First, the resin molded product 1 according to the second embodiment is manufactured by injection molding using an injection molding machine (not shown). In the process of manufacturing the resin molded product 1, a step portion 41 having a step in the +Z direction (one direction) is formed in the middle of the gate portion 4 extending along the Y direction.

[0041] Next, a transfer robot (not shown) is used to transfer the resin molded product 1 produced using the injection molding device to a parts table 15 provided in an automatic assembly device (not shown). At this time, the first part 5, the second part 6A, the third part 6B, and the fourth part 7 are supported on the parts table 15, and the runner part 3 and the gate part 4 are not supported on the parts table 15. Note that instead of the transfer robot, the resin molded product 1 may be transferred to the parts table 15 using a robot arm (not shown) provided in the automatic assembly device.

[0042] Next, pushing member 16 provided in the automated assembly device pushes runner portion 3 in the -Z direction, thereby separating first component 5, second component 6A, third component 6B, and fourth component 7 all at once in the +Z direction (one direction) from gate portion 4 and runner portion 3. First component 5, second component 6A, third component 6B, and fourth component 7 separated from gate portion 4 and runner portion 3 are supported on component stand 15 in the orientation (posture) they had when they were separated.

[0043] Next, fingers 12 of a robot arm provided in the automatic assembly device place the first component 5 separated from the gate portion 4 and the runner portion 3 on an assembly jig (not shown) provided in the automatic assembly device while maintaining the orientation (posture) of the first component 5 at the time of separation. Next, fingers 12 of the robot arm assemble the second component 6A separated from the gate portion 4 and the runner portion 3 to the first shaft portion 52A (see FIG. 3(a)) of the first component 5 placed on the assembly jig while maintaining the orientation of the second component 6A at the time of separation. Next, fingers 12 of the robot arm assemble the third component 6B separated from the gate portion 4 and the runner portion 3 to the second shaft portion 52B (see FIG. 3(a)) of the first component 5 placed on the assembly jig while maintaining the orientation of the first component 6A at the time of separation. Then, similar to the first embodiment, fingers 12 of the robot arm assemble the fourth component 7 separated from the gate portion 4 and the runner portion 3 to the first component 5 placed on the assembly jig while maintaining the orientation of the fourth component 7 at the time of separation.

[0044] In this manner, assembly 10 can be produced by assembling first part 5, second part 6A, third part 6B, and fourth part 7, which are separated from gate 4 and runner 3 in the +Z direction (one direction). Furthermore, assembly 10 can be easily produced by performing only relative translation of the multiple parts constituting assembly 10 from molding to assembly, without rotational movement of each part about the X axis and the Y axis. In the second embodiment, as in the first embodiment, the direction of the step of step 41 formed in gate 4 coincides with the direction in which each part of resin molded product 1 separates from gate 4 and runner 3 in the +Z direction (one direction). The +Z direction vector indicating the direction of the step of step 41 and the +Z direction vector indicating the direction in which each part of resin molded product 1 separates from gate 4 and runner 3 are parallel to each other.

[0045] As described above, when the pushing member 16 pushes the runner portion 3 in the -Z direction, each component of the resin molded product 1 supported by the component stand 15 moves in the +Z direction relative to the runner portion 3. Therefore, as in the first embodiment, the gate portion 4 connected to each component of the resin molded product 1 elastically deforms, causing the highest stress concentration to occur at the tip portion 42 of the gate portion 4. When the stress generated at the tip portion 42 of the gate portion 4 reaches the breaking stress of the resin (the material of the resin molded product 1), the tip portion 42 of the gate portion 4 breaks, and each component of the resin molded product 1 is separated collectively from the gate portion 4 and runner portion 3 in the +Z direction (one direction).

[0046] When the pushing member 16 collectively separates each component of the resin molded product 1 from the gate portion 4 and the runner portion 3, the gate portion 4 is prone to elastic deformation, so that the elastic force of the gate portion 4 can be utilized to easily break the tip portion 42 of the gate portion 4. Therefore, the pushing force of the pushing member 16 required to separate each component of the resin molded product 1 from the gate portion 4 and the runner portion 3 can be reduced without reducing the cross-sectional area of the gate portion 4. As a result, the first component 5, the second component 6A, the third component 6B, and the fourth component 7 connected to the runner portion 3 can be easily separated from the runner portion 3 without reducing the resin injectability during molding.

[0047] As described above, according to the manufacturing method of the resin molded product 1 and assembly 10 of the second embodiment, similar to the first embodiment, multiple parts connected to the runner portion 3 can be easily separated from the runner portion 3 without reducing the resin injectability during molding.

[0048] <<Third Embodiment>> Next, a third embodiment will be described. Since the individual components in the third embodiment have the same configuration as those in the first embodiment, they will be described using the same reference numerals as those in the first embodiment.

[0049] <Configuration of resin molded products> FIG. 9 is an external view of a resin molded product 1 according to a third embodiment. FIG. 9(a) is a plan view of the resin molded product 1. FIG. 9(b) is a perspective view of the resin molded product 1. As shown in FIGS. 9(a) and 9(b), the resin molded product 1 according to the third embodiment has a spool portion 2, a runner portion 3, multiple gate portions 4, a first component 5, a second component 6A, a third component 6B, and a fourth component 7. The resin molded product 1 is produced by injection molding using a resin material. The spool portion 2, the runner portion 3, the first component 5, the second component 6A, the third component 6B, and the fourth component 7 are formed in the same manner as in the first embodiment.

[0050] FIG. 10 is an enlarged view of the second component 6A and the gate portion 4. FIG. 10(a) is an enlarged plan view of the second component 6A and the gate portion 4. FIG. 10(b) is an enlarged side view of the second component 6A and the gate portion 4. As shown in FIGS. 10(a) and 10(b), the gate portion 4 is formed to extend in a direction intersecting the Z direction, specifically, along the Y direction perpendicular to the Z direction. The two gate portions 4 are disposed symmetrically with respect to the second component 6A and are formed to be connected to both sides of the second component 6A in the Y direction.

[0051] A stepped portion 41 having a step in the Z direction is formed in the middle of the gate portion 4. The stepped portion 41 extends in the Z direction. In other words, the stepped portion 41 extends in a staircase pattern in the middle of the gate portion 4. The cross-sectional area of the tip of the gate portion 4 decreases as it approaches the second component 6A. The cross-sectional area of the tip 42 of the gate portion 4 connected to the second component 6A is smaller than the cross-sectional area of the portion of the gate portion 4 excluding the tip 42. The tip 42 of the gate portion 4 is connected to the side surface of the end of the second component 6A on the -Z direction side. Because the gate portion 4 has such a shape, when the second component 6A is torn off from the gate portion 4 and the runner portion 3, the tip 42 of the gate portion 4 breaks preferentially over other portions of the gate portion 4. When the tip 42 of the gate portion 4 breaks, the second part 6A is separated from the gate portion 4 and the runner portion 3 in the +Z direction (one direction) perpendicular to the plane (XY plane) including the frame-shaped runner portion 3.

[0052] The four gate portions 4 connected to the first component 5 are formed in the same manner as the two gate portions 4 connected to the second component 6A, and therefore detailed description thereof will be omitted. The four gate portions 4 connected to the first component 5 are arranged in the same manner as in the first embodiment. The two gate portions 4 connected to the third component 6B are formed in the same manner as the two gate portions 4 connected to the second component 6A, and therefore detailed description thereof will be omitted. The two gate portions 4 connected to the third component 6B are arranged in the same manner as in the first embodiment. The four gate portions 4 connected to the fourth component 7 are formed in the same manner as the two gate portions 4 connected to the second component 6A, and therefore detailed description thereof will be omitted. The four gate portions 4 connected to the fourth component 7 are arranged in the same manner as in the first embodiment.

[0053] As in the first embodiment, assembly 10 can be produced by assembling first component 5, second component 6A, third component 6B, and fourth component 7, which have been separated from gate 4 and runner 3 in the +Z direction (one direction). In other words, assembly 10 can be produced by assembling first component 5, second component 6A, third component 6B, and fourth component 7 while maintaining the orientations (postures) of the components when they were separated from gate 4 and runner 3. The method for manufacturing assembly 10 according to the third embodiment is similar to that of the first embodiment, and therefore a detailed description thereof will be omitted. In the third embodiment, as in the first embodiment, the direction of the step of step portion 41 formed in gate 4 and the direction in which each component of resin molded product 1 is separated from gate 4 and runner 3 coincide in the +Z direction (one direction). Furthermore, the +Z direction vector indicating the direction of the step of the step portion 41 and the +Z direction vector indicating the direction in which each part of the resin molded product 1 is separated from the gate portion 4 and the runner portion 3 are in a parallel relationship.

[0054] FIG. 11 is an explanatory diagram showing the process of separating the second component 6A from the gate portion 4 and the runner portion 3. FIG. 11(a) is an explanatory diagram showing the state before the second component 6A is separated from the gate portion 4 and the runner portion 3. FIG. 11(b) is an explanatory diagram showing the state during the separation of the second component 6A from the gate portion 4 and the runner portion 3. FIG. 11(c) is an explanatory diagram showing the state after the second component 6A has been separated from the gate portion 4 and the runner portion 3. As shown in FIGS. 11(a) and 11(b), when the fingers 12 (not shown in FIG. 11) of the robot arm grasp the second component 6A and pull it in the +Z direction, the second component 6A moves relative to the runner portion 3 in the +Z direction. At this time, the gate portion 4 elastically deforms, causing the highest stress concentration to occur at the tip 42 of the gate portion 4. When the stress generated at the tip 42 of the gate portion 4 reaches the breaking stress of the resin (the material of the resin molded product 1), the tip 42 of the gate portion 4 breaks, and the second part 6A is torn off from the gate portion 4 and the runner portion 3, as shown in Figure 11(c).

[0055] In this embodiment, the gate portion 4 has a step portion 41 with a step in the +Z direction (one direction) and extends along the Y direction perpendicular to the +Z direction. When the fingers 12 of the robot arm tear off the second component 6A from the gate portion 4 and the runner portion 3, the gate portion 4 is easily elastically deformed, so that the elastic force of the gate portion 4 can be used to easily break the tip portion 42 of the gate portion 4. Therefore, the gripping force of the fingers 12 required to separate the second component 6A from the gate portion 4 and the runner portion 3 can be reduced without reducing the cross-sectional area of the gate portion 4. This allows the second component 6A connected to the runner portion 3 to be easily separated from the runner portion 3 without reducing resin injectability during molding. Furthermore, the gate portion 4 connected to the first component 5, the gate portion 4 connected to the third component 6B, and the gate portion 4 connected to the fourth component 7 are formed in the same manner as the gate portion 4 connected to the second component 6A. Therefore, the first component 5, the third component 6B, and the fourth component 7 connected to the runner portion 3 can be easily separated from the runner portion 3 without reducing the resin injectability during molding.

[0056] As described above, according to the manufacturing method of the resin molded product 1 and assembly 10 of the third embodiment, similar to the first embodiment, multiple parts connected to the runner portion 3 can be easily separated from the runner portion 3 without reducing the resin injectability during molding.

[0057] In the third embodiment described above, the assembly 10 may be manufactured using the manufacturing method for the assembly 10 according to the second embodiment.

[0058] In each of the above-described embodiments, the resin molded product 1 has four components, but is not limited to this. For example, the resin molded product may have two components, three components, or five or more components. In this case, the multiple components in the resin molded product are configured to be separated from the multiple gate portions and runner portions in the +Z direction (one direction) and assembled.

[0059] In each of the above-described embodiments, the assembly 10 may be an assembly part to be incorporated into any device (for example, a printing device, a semiconductor manufacturing device, an imaging device, etc.), or may be a finished product.

[0060] <<Other embodiments>> The disclosure of the present embodiment includes the following examples of resin molded products and configurations represented by examples of manufacturing methods for assembled products.

[0061] <Configuration 1> A resin molded product having a plurality of components, a plurality of gate portions formed by connecting the plurality of components, and a runner portion formed by connecting the plurality of gate portions, the plurality of components are configured to be separated from the plurality of gate portions and the runner portion in one direction and assembled; The gate portion has a step portion having a step in the one direction and extends in a direction intersecting the one direction.

[0062] <Configuration 2> 2. The resin molded product according to claim 1, wherein the step portion extends in a direction inclined with respect to the one direction.

[0063] <Configuration 3> 3. The resin molded product according to claim 1, wherein a cross-sectional area of a tip of the gate portion connected to the component is smaller than a cross-sectional area of a portion of the gate portion excluding the tip.

[0064] <Configuration 4> 4. The resin molded product according to any one of configurations 1 to 3, wherein the part is separated from the gate portion and the runner portion in the one direction by breaking a tip portion of the gate portion connected to the part.

[0065] <Configuration 5> 5. The resin molded product according to claim 3, wherein the tip portion is connected to a side surface of an end portion of the part in the one direction.

[0066] <Configuration 6> 6. The resin molded product according to any one of configurations 1 to 5, wherein the gate portion is formed so as to be connected to both sides of the component in a direction intersecting the one direction.

[0067] <Configuration 7> a step of producing a resin molded product having a plurality of parts, a plurality of gate portions formed by connecting the plurality of parts, and a runner portion formed by connecting the plurality of gate portions; unidirectionally separating the components from the gates and runners; assembling the plurality of parts separated in one direction from the plurality of gate portions and the runner portion to produce an assembly; and The method for manufacturing an assembly, wherein the gate portion has a step portion having a step in the one direction and extends along a direction intersecting the one direction.

[0068] <Configuration 8> A method for manufacturing an assembly according to aspect 7, wherein the step portion extends in a direction inclined relative to the one direction.

[0069] <Configuration 9> The method for manufacturing an assembly according to configuration 7 or 8, wherein the cross-sectional area of the tip of the gate portion connected to the part is smaller than the cross-sectional area of the portion of the gate portion excluding the tip.

[0070] <Configuration 10> 10. The method for manufacturing an assembly according to any one of configurations 7 to 9, wherein the part is separated from the gate portion and the runner portion in the one direction by breaking a tip portion of the gate portion connected to the part.

[0071] <Configuration 11> A method for manufacturing an assembly according to aspect 9 or 10, wherein the tip portion is connected to a side surface of the end portion of the part in the one direction.

[0072] <Configuration 12> A method for manufacturing an assembly according to any one of configurations 7 to 11, wherein the gate portion is formed so as to be connected to both sides of the part in a direction intersecting the one direction. [Explanation of symbols]

[0073] 1 Resin molded products 3. Runners 4 Gate section 5. First Part 6A Second part 6B Third part 7 Fourth Part 10 Assembly 41 Step

Claims

1. A resin molded product having a plurality of components, a plurality of gate portions formed by connecting the plurality of components, and a runner portion formed by connecting the plurality of gate portions, the plurality of components are configured to be separated from the plurality of gate portions and the runner portion in one direction and assembled; The gate portion has a step portion having a step in the one direction and extends in a direction intersecting the one direction.

2. The resin molded product according to claim 1 , wherein the step portion extends in a direction inclined with respect to the one direction.

3. The resin molded product according to claim 1 , wherein a cross-sectional area of a tip of the gate connected to the component is smaller than a cross-sectional area of a portion of the gate excluding the tip.

4. The resin molded product according to claim 1 , wherein the part is separated from the gate and the runner in the one direction by breaking a tip of the gate connected to the part.

5. The resin molded product according to claim 3 or 4, wherein the tip portion is connected to a side surface of an end portion of the component in the one direction.

6. The resin molded product according to claim 1 , wherein the gate portion is formed so as to be connected to both sides of the component in a direction intersecting the one direction.

7. a step of producing a resin molded product having a plurality of parts, a plurality of gate portions formed by connecting the plurality of parts, and a runner portion formed by connecting the plurality of gate portions; unidirectionally separating the components from the gates and runners; assembling the plurality of parts separated in one direction from the plurality of gate portions and the runner portion to produce an assembly; and The method for manufacturing an assembly, wherein the gate portion has a step portion having a step in the one direction and extends along a direction intersecting the one direction.

8. The method for manufacturing an assembly according to claim 7 , wherein the step portion extends in a direction inclined with respect to the one direction.

9. The method for manufacturing an assembly according to claim 7 , wherein a cross-sectional area of a tip of the gate portion connected to the component is smaller than a cross-sectional area of a portion of the gate portion excluding the tip.

10. The method for manufacturing an assembly according to claim 7 , wherein the part is separated from the gate portion and the runner portion in the one direction by breaking a tip portion of the gate portion connected to the part.

11. The method for manufacturing an assembly according to claim 9 or 10, wherein the tip portion is connected to a side surface of an end portion of the part in the one direction.

12. The method for manufacturing an assembly according to claim 7 , wherein the gate portions are formed so as to be connected to both sides of the part in a direction intersecting the one direction.

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