Method for manufacturing vehicle module, vehicle module, and injection molding device

Abstract

To provide a technology that enables a manufacture of a vehicle module made up of a plurality of vehicle components.SOLUTION: In a method for manufacturing a vehicle module including at least first and second vehicle components using an injection molding device having a fixed mold 222, a movable mold 242, and an intermediate mold 265 positioned between these molds and capable of being molded with each other, one of the first and second vehicle components includes a vehicle lamp cover, the first vehicle component is injection molded using the fixed mold 222 and the movable mold 242, in a state where the first vehicle member is held on the fixed mold 222 side of the intermediate mold 265 and the mold is opened, the intermediate mold 265 is rotated so that the first vehicle member faces the movable mold 242, and with the use of the movable mold 224 and the intermediate mold 265, the second vehicle member is injection molded so that the second vehicle member is joined to the first vehicle member.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a technique for manufacturing a module made up of a plurality of members. [Background technology]

[0002] A conventional technique of this type is the injection molding machine described in Patent Document 1. This injection molding machine is characterized in that a rotary platen on which an intermediate mold that rotates about an axis perpendicular to the mold opening / closing direction can be attached is provided between a first platen on which a first mold can be attached and a second platen on which a second mold can be attached, a first injection unit is provided outside the first platen, a second injection unit is provided outside the second platen, and a third injection unit whose total weight is smaller than that of the first injection unit is provided. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-132812 Summary of the Invention [Problem to be solved by the invention]

[0004] The problem to be solved by the embodiments of the present invention is to provide a technology capable of manufacturing a vehicle module consisting of a plurality of vehicle components. Other problems and novel features will become apparent from the description of this specification and the accompanying drawings. [Means for solving the problem]

[0005] A method for manufacturing a vehicle module according to one embodiment is a method for manufacturing a vehicle module including at least first and second vehicle components using an injection molding device having a first mold, a second mold, and an intermediate mold positioned between the first and second molds and capable of being molded relative to each other, wherein one of the first and second vehicle components includes a vehicle lamp cover, and the first vehicle component is injection molded using the first mold and the intermediate mold, and while the first vehicle component is held on the first mold side of the intermediate mold and the mold is opened, the intermediate mold is rotated so that the first vehicle component faces the second mold, and the second vehicle component is injection molded using the second mold and the intermediate mold so that the second vehicle component is joined to the first vehicle component. [Brief explanation of the drawings]

[0006] [Figure 1] 1 is a block diagram showing a configuration of an injection molding apparatus according to a first embodiment. [Figure 2] FIG. 1 is a schematic plan view showing a configuration of an injection molding apparatus according to a first embodiment. [Figure 3] FIG. 2 is a schematic side view showing the configuration of an intermediate platen of the mold clamping unit according to the first embodiment. [Figure 4] 1 is a schematic view showing a vehicle module molded by an injection molding apparatus according to a first embodiment. [Figure 5] 2A to 2C are diagrams for explaining a method for manufacturing a vehicle module using an injection molding apparatus according to the first embodiment. [Figure 6] 10A and 10B are diagrams for explaining a method for manufacturing a vehicle module using an injection molding apparatus according to a second embodiment. [Figure 7] 10A and 10B are diagrams illustrating a method for manufacturing a vehicle module using an injection molding apparatus according to a third embodiment. [Figure 8] 10A and 10B are diagrams for explaining a method for manufacturing a vehicle module using an injection molding apparatus according to a fourth embodiment. [Figure 9]10A and 10B are diagrams for explaining a method for manufacturing a vehicle module by an injection molding apparatus according to a fifth embodiment. [Figure 10] FIG. 10 is a schematic view showing a vehicle module molded by an injection molding apparatus according to a fifth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0007] Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the present invention is not limited to the following embodiments. For clarity of explanation, the following description and drawings have been appropriately simplified. In each drawing, the same elements are given the same reference numerals, and duplicate explanations are omitted as necessary. Furthermore, hatching has been omitted in some areas to avoid cluttering the drawings.

[0008] First Embodiment (Configuration of injection molding equipment) The overall configuration of the injection molding apparatus according to this embodiment will be described below. Fig. 1 is a block diagram showing the configuration of the injection molding apparatus according to this embodiment.

[0009] 1, the injection molding apparatus 1 according to this embodiment includes three injection units 10A to 10C, a mold clamping unit 20, and a control unit 30 that controls the driving of the injection units 10A to 10C and the mold clamping unit 20. When there is no need to distinguish between the injection units 10A to 10C, the injection units will be referred to as injection unit 10 in the following description.

[0010] The injection unit 10 has a heating cylinder, a screw, etc., and is provided adjacent to a clamping unit 20 to which a mold corresponding to the injection unit itself, the details of which will be described later, is attached. The injection unit 10 is a device that melts and kneads resin pellets fed into a hopper connected to the heating cylinder, and then injects the molten resin into a mold from a nozzle to obtain a desired resin molded product.

[0011] In this embodiment, three different resin molded products are molded using injection units 10A to 10C, respectively. Each molded resin molded product is a vehicle component constituting a vehicle module such as an automobile, e.g., a long front module or rear module that covers almost the entire width of the vehicle. The three vehicle components are joined together, or any two of them are joined to the remaining one, to form a single vehicle module. To mold such a vehicle module, it is preferable to use a large injection molding apparatus 1 according to this embodiment, for example, one with a clamping force of 2000 to 5000 tonnes, preferably 2400 tonnes or more. In the injection molding apparatus 1, any one of injection units 10A to 10C is arranged as an opposing machine, facing the others. Details of this arrangement and the vehicle module will be described later.

[0012] The control device 30 is connected to the injection device 10, the mold clamping device 20, etc., and functions as a molding control unit capable of controlling these devices. Specifically, it drives and controls various actuators provided in the injection device 10 and the mold clamping device 20. It is also connected to switches such as limit switches and sensors. The control device 30 has hardware such as a central processing unit (CPU), read-only memory (ROM), and random access memory (RAM), not shown, which cooperate to control the series of device operations described above. The control device 30 may also have an input / output unit to receive input from a user and output it via a display, for example, to input and display various settings for the injection molding apparatus 1. The control device 30 may be incorporated into any of the injection devices 10A to 10C or the mold clamping device 20, or may be independently constructed as an information processing device such as a personal computer (PC).

[0013] Next, the arrangement of injection units 10A to 10C and the configuration of mold clamping unit 20 will be described in detail as part of the configuration of injection molding apparatus 1. Fig. 2 is a schematic plan view showing the configuration of injection molding apparatus 1 according to this embodiment. Fig. 3 is a schematic side view showing the configuration of an intermediate platen of the mold clamping unit according to this embodiment. Fig. 3 shows an intermediate platen 26 of mold clamping unit 20 as seen from a side direction perpendicular to the mold opening / closing direction and the up-down direction, as indicated by the symbol X.

[0014] As shown in Fig. 2, the injection molding apparatus 1 according to this embodiment has injection units 10A to 10C and a mold clamping unit 20 provided on a rectangular bed 40. In this embodiment, injection units 10A and 10B are disposed adjacent to each other on the right side of the drawing, and injection unit 10C is disposed on the left side of the drawing so that its nozzle faces injection units 10A and 10B. The mold clamping unit 20 is disposed between injection units 10A and 10B and injection unit 10C. The nozzle of each injection unit 10 faces the mold clamping unit 20 so as to inject molten resin into a mold of the mold clamping unit 20, which will be described later.

[0015] The mold clamping unit 20 has a fixed platen 22 fixed on a bed 40 and a movable platen 24 that is movable toward and away from the fixed platen 22 along the mold opening / closing direction X. The mold clamping unit 20 also has an intermediate platen 26 that is disposed between the fixed platen 22 and the movable platen 24 and that, like the movable platen 24, is movable toward and away from the fixed platen 22 along the mold opening / closing direction X. The fixed platen 22 has hydraulically operated mold clamping cylinders (not shown) built in near each of its four corners in a plane perpendicular to the mold opening / closing direction X, and the rods of the mold clamping cylinders also form tie bars (not shown). A total of four tie bars are inserted near the four corners of the intermediate platen 26 and also near the four corners of the movable platen 24, and guide the movement of the movable platen 24 and the intermediate platen 26.

[0016] A mold opening and closing mechanism 52 is provided on one side surface of the fixed platen 22 and the movable platen 24 parallel to the mold opening and closing direction X. The mold opening and closing mechanism 52 includes a ball screw 521 that is threadedly engaged with brackets provided on the side surfaces of the fixed platen 22 and the movable platen 26 and inserted therethrough so as to be rotatable relative to each other, and a servo motor (not shown) that is provided on the bed 40. When the ball screw 521 is rotated by the servo motor, the movable platen 24 moves on the bed 40 along the mold opening and closing direction X while being guided by the tie bars relative to the fixed platen 22.

[0017] Further, a mold opening and closing mechanism 54 is provided on one side surface of the movable platen 24 and the intermediate platen 26 parallel to the mold opening and closing direction X. The mold opening and closing mechanism 54 includes a ball screw 541 threadedly engaged with ball screw nuts provided on brackets provided on the side surfaces of the movable platen 24 and the intermediate platen 26 and inserted therethrough so as to be relatively rotatable, and a servo motor (not shown) provided on the side surface of the movable platen 24. When the ball screw 541 is rotated by the servo motor, the intermediate platen 26 moves on the bed 40 along the mold opening and closing direction X while being guided by the tie bars relative to the movable platen 24.

[0018] Each servo motor of the mold opening and closing mechanisms 52, 54 has a rotary encoder that detects the rotation angle, and the position of the movable platen 24 or intermediate platen 26 corresponding to this rotary encoder in the mold opening and closing direction X can be detected. These servo motors are connected to the control device 30 and are controllable.

[0019] The mold opening and closing mechanisms 52, 54 may at least partially use a toggle mechanism or a rack and pinion mechanism, and the actuators thereof are not limited to electric motors such as servo motors, but may also use hydraulic cylinders. The mold opening and closing mechanisms 52, 54 may be connected in any manner as long as the movable platen 24 and the intermediate platen 26 can move along the mold opening and closing direction X.

[0020] As shown in FIG. 3 , the intermediate platen 26 has an upper frame 261 through which two upper tie bars 62 (only one of which is shown in the figure) are inserted, and a lower frame 262 through which two lower tie bars 64 (only one of which is shown in the figure) are inserted. A rotating platen 263 is provided between these frames and is rotatable relative to the upper and lower frames 261, 262. The rotating platen 263 is configured to be rotatable around a rotation axis (not shown) perpendicular to the mold opening / closing direction X and the up-down direction, and a rotation drive device 264 such as a motor is attached to the rotation axis. Therefore, the rotating platen 263 can be rotated vertically around the rotation axis by the rotation drive device 264, more specifically, within a range of at least 180 degrees. The rotation drive device 264 can be controlled by the control device 30. The rotation drive device 264 may be provided on the upper surface of the intermediate platen 26, forming a rotating platen in an area where the tie bars 62, 64 are not inserted. Furthermore, the turntable 263 is not limited to one that rotates around a vertical axis of rotation, and the turntable 263 may be rotatable around a horizontal axis of rotation.

[0021] A fixed mold 222 is attached to the end face of the fixed platen 22 facing the intermediate platen 26, i.e., the mold attachment surface. Similarly, a movable mold 242 is attached to the end face of the movable platen 24 facing the intermediate platen 26. Meanwhile, intermediate molds 265 are attached to the end face of the rotating platen 263 of the intermediate platen 26 facing the fixed platen 22 and the end face of the rotating platen 263 facing the movable platen 24, respectively. Both of the two intermediate molds 265 are formed so as to be able to be mated with the fixed mold 222 and the movable mold 242.

[0022] In this embodiment, the fixed mold 222 and the opposing intermediate mold 265 are mated and clamped to form first and second cavities. The first cavity is formed so that injected resin can flow therein to mold a lamp cover as a vehicle component, and the second cavity is formed so that injected resin can flow therein to mold a center member as a vehicle component. A runner (a flow path mainly consisting of a hot runner) 224 and a gate that can communicate with the first cavity are formed in the fixed platen 22 and the fixed mold 222. Molten resin for the lamp cover is injected from the injection device 10A through the runner 224 and the gate connected to the runner 224, allowing the molten resin to flow into the first cavity. Furthermore, a runner 226 and a gate that can communicate with the second cavity are formed in the fixed platen 22 and the fixed mold 222. The molten resin for the center member is injected from the injection device 10B through the runner 226 and the gate, and the molten resin can flow into the second cavity.

[0023] Meanwhile, a third cavity is defined by mating the movable mold 242 with the opposing intermediate mold 265. Specifically, the third cavity is defined in advance with the lamp cover and center member held between the two molds. Therefore, portions of the movable mold 242, intermediate mold 265, lamp cover, and center member each become cavity surfaces, defining the third cavity. In other words, the third cavity is defined by dividing the space defined between the movable mold 242 and the opposing intermediate mold 265 by the lamp cover and center member. The third cavity is formed so that injected resin can flow into it to mold a lamp cover frame member as a vehicle component. A runner 244 and a gate are formed in the movable platen 24 and the movable mold 242, which can communicate with the third cavity for molding the lamp cover frame member. The molten resin for the lamp cover frame member is injected from the injection device 10C through the runner 244 and the gate, and thereby the molten resin can be made to flow into the third cavity.

[0024] Injection units 10A and 10B are configured to be movable relative to the fixed mold 222. On the other hand, injection unit 10C is configured to be movable relative to the movable mold 242 and to be movable on bed 40 in conjunction with the mold opening / closing movement of mold clamping unit 20, i.e., the movement of movable mold 242 toward the fixed mold 222. During continuous molding in this embodiment, the nozzles of injection units 10A and 10B are always in contact with the fixed mold 222, and the nozzle of injection unit 10C is always in contact with the movable mold 242. However, the nozzles of injection units 10A, 10B, and 10C may be configured so that they come into contact with the mold only during injection.

[0025] Next, a brief description will be given of a vehicle module molded by the injection molding apparatus 1 according to this embodiment. FIG. 4 is a schematic diagram illustrating a vehicle module molded by the injection molding apparatus according to this embodiment. The vehicle module designated by the reference character F in FIG. 4 is a so-called vehicle front module. The front module F includes two headlamp covers F1 (first vehicle components, hereinafter simply referred to as lamp covers F1) that cover the front of the headlamps (headlights) incorporated into the vehicle, i.e., the forward-moving side of the vehicle, and a long center member F2 (second vehicle component), such as a front grille, positioned between and connected to the two lamp covers F1. The front module F also includes a lamp cover frame member F3 (third vehicle component) that surrounds and joins to the edge of the corresponding lamp cover F1 and also joins to the center member F2 to hide the connection with the back side of the lamp cover F1. In other words, the center member F2 is connected to the lamp cover F1 via the lamp cover frame member F3. The front module F is formed by integrating the lamp cover F1, center member F2, and lamp cover frame member F3 through at least an injection molding process. The lamp cover F1 and center member F2 are not directly joined, but the mold may be designed to join them. The center member F2 may also include at least a portion of the lamp housing main body (lamp body) that houses the headlamp in the vehicle. Furthermore, although not shown in FIG. 4, the center member F2 or lamp cover frame member F3 of the front module F may be provided with a protruding edge having bolt holes for securing the front module F to the vehicle, as needed.

[0026] The lamp cover F1 is preferably made of a transparent or translucent resin with high optical transparency. Considering strength, polycarbonate is suitable, but methacrylic resin (acrylic resin) or other resins with excellent optical properties may also be used. On the other hand, the lamp cover frame member F3 and center member F2 do not need to be made of transparent resin. They may be made of polycarbonate, like the lamp cover F1, but a resin material other than that of the lamp cover F1, including a grade containing reinforcing fibers, may also be used. Examples include glass fiber-containing grades of ABS resin and glass fiber-containing grades of polypropylene.

[0027] If the lamp cover F1 and the center member F2 and / or lamp cover frame member F3 are both made of polycarbonate, there is no need to pay much attention to the mold temperature. However, if these resin materials are different and the mold cooling temperatures are different, measures such as inserting a heat insulating material between the first to third cavities in the mold or controlling the temperature near at least one of the cavity surfaces where the material is injected for each molding cycle may be taken.

[0028] Furthermore, by using a transparent resin for at least a portion of the center member F2 and / or the lamp cover frame member F3, it becomes possible to attach a sensor such as a distance sensor behind that portion. These members may be molded using a transparent resin and by applying a patterning process, including an embossing process, to the molds (fixed mold 222, intermediate mold 262). On the other hand, when using a resin material of the same color as or different from the color of the vehicle body for the center member F2 and / or the lamp cover frame member F3, by molding using a colored resin of the same color as the vehicle body or a different color, i.e., a resin with low light transmittance, the front module can be delivered and used as an automotive part as is without additional painting.

[0029] Furthermore, by using the same resin material for the lamp cover F1, center member F2, and lamp cover frame member F3, the bonding strength between them can be ensured.Furthermore, even if the center member F2 is made of ABS or an ABS-based resin, the bonding strength can be ensured because both are amorphous resins.

[0030] Also, the front bumper may be integrally molded as a front module by including it in the center member F2, etc. It goes without saying that the front module F described above is one example, and the number and position of the lamp covers F1, the shape of the center member F2, etc. can be changed as appropriate depending on the vehicle model, that is, the mold can be changed.

[0031] (Operation of injection molding machine) Next, the manufacturing method of the front module F using the injection molding apparatus 1 according to this embodiment will be described in detail with reference to the drawings, showing the molding sequence of one front module molded product. FIG. 5 is a diagram for explaining the manufacturing method of a vehicle module using the injection molding apparatus according to this embodiment. FIG. 5 is a schematic plan view showing the injection molding apparatus 1. The two reference numerals 70 shown in FIG. 5(d) denote an ejector device and a pair of ejector pins for removing the molded front module F from the mold by pressing it from its rear surface. Note that the main operating element of the injection molding apparatus 1 described below is the control device 30. For ease of understanding, only the lamp cover frame member F3 is shown hatched in FIG. 5. Note that the ejector device may be provided inside the mold.

[0032] As described above, the lamp cover F1 and the center member F2 are injection molded (primary molding) in the first and second cavities defined between the fixed mold 222 and the intermediate mold 265. Then, the intermediate mold 265 is opened relative to the fixed mold 222. At this time, as shown in Fig. 5(a), the lamp cover F1 and the center member F2 are held in the intermediate mold 265. Next, as shown in Fig. 5(b), the rotating plate 263 of the intermediate plate 26 is rotated 180 degrees, and the intermediate mold 265 holding the lamp cover F1 and the center member F2 is opposed to, i.e., directly facing, the movable mold 242 so that they can be mated.

[0033] After the rotation, as shown in Fig. 5(c), the movable platen 24 and the intermediate platen 26 are moved in the mold closing direction, i.e., toward the fixed platen 22, and the mold clamping unit 20 enters a mold closing state. In the mold closing state, the mold is clamped by the mold clamping cylinder. After mold clamping, the injection units 10A to 10C inject molten resin into each cavity through the runners 224, 226, 244 and the gates corresponding to each runner.

[0034] Note that the resin injection from each injection unit 10 may be simultaneous. However, the timing of the start of injection may be staggered so that at least the lamp cover F1 and the center member F2 complete their cooling at the same time. Generally, the center member F2, which has a larger volume, requires a longer cooling time. Therefore, the center member F2 may be injected first, and then injection to mold the lamp cover F1, i.e., injection from the injection unit 10A, may be performed after a predetermined delay time has elapsed. Furthermore, because the projected area of ​​the molded product combining the two lamp covers F1 and the center member F2 is quite large, staggering the injection timing has the advantage of allowing for smaller mold clamping force than simultaneous injection.

[0035] Resin is injected by the injection device 10C through the runner 224 and the gate, causing resin to flow into the third cavity, and the lamp cover frame member F3 is joined to the lamp cover F1 and center member F2 held in the intermediate mold 265 for integral molding (secondary molding), thereby obtaining the front module F. Meanwhile, resin is injected by the injection device 10A and injection device 10B, causing resin to flow into the first and second cavities through the runners 224 and 226, etc., and a new lamp cover F1 and center member F2 are molded (next primary molding).

[0036] After injection, the front module F is cooled for a predetermined time, and then the movable platen 24 and intermediate platen 26 are moved back to their original positions, that is, in the mold opening direction. At this time, the front module F is held by the movable mold 242 and released from the mold. At this time, as shown in FIG. 5(d), the ejector pins of the ejector unit 70 provided on the movable platen 24 are moved forward and protrude from the cavity surface of the movable mold 242, releasing the front module F from the mold. The released front module F is held by a removal robot (not shown) and removed to the outside of the injection molding apparatus 1. Meanwhile, after the front module F is released from the mold, the injection molding apparatus 1 returns to a state in which the lamp cover F1 and the center member F2 are held by the intermediate mold 265 on the fixed mold 222 side, as shown in FIG. 5(a).

[0037] According to the present embodiment described above, it is possible to manufacture the front module F including the lamp cover F1 using the injection molding apparatus 1 equipped with the opposed injection units 10A to 10C and the mold clamping unit 20. Therefore, compared to the case where the lamp cover F1, the lamp cover frame member F3, etc. are molded and delivered separately, it is possible to reduce the number of assembly steps, and therefore the assembly cost.

[0038] It should be noted that the lamp cover F1 and center member F2, which normally require a longer molding time (including cooling time) than the lamp cover member F2, are expected to be molded in the cavity between the fixed mold 222 and intermediate mold 265, and in the cavity between the movable mold 242 and intermediate mold 265. However, due to the three-dimensional structures of the lamp cover F1 and center member F2, it is not easy to core-back mold the lamp cover frame member F3. Therefore, by molding the lamp cover F1 and center member F2 on the same side, it is possible to obtain the front module F with a simple mold configuration without using a mold with a core-back structure.

[0039] Furthermore, if the lamp cover F1 and the center member F2 and / or lamp cover frame member F3 are made of the exact same resin material (transparent resin material), they can be molded using one injection device. However, from a design perspective, it is unlikely that the entire front module F will be molded using the same transparent resin material. Therefore, if the entire front module F is not molded using the same resin, the nozzle and heating cylinder temperatures may differ between the lamp cover F1 and other parts, and considering the molding conditions for both (settings for injection, pressure retention, etc.), it is preferable to use multiple injection devices as in this embodiment.

[0040] Furthermore, for aesthetic reasons, the lamp covers F1 and center member F2 have larger areas on the vehicle front side than the lamp cover frame member F3, and a larger portion of the lamp cover frame member F3 wraps around to the back side of the lamp covers F1 and center member F2. However, this structure increases the contact area between the lamp covers F1 and center member F2 and the lamp cover frame member F3, making it possible to further increase the joining strength, or bonding strength.

[0041] In addition, recesses, grooves, etc. may be formed on the cavity surface of the mold that forms the joining portion of the lamp cover F1 and the center member F2, i.e., by roughening the surface, the bonding strength with other members when the lamp cover frame member F3 is later injection molded can be improved.

[0042] Furthermore, although the front module F has been described as including two lamp covers F1, this is not limited to this. For example, only one lamp cover F1 may be provided extending in the longitudinal direction of the front module F, and the lamp cover frame member F3 may be formed to surround the edge of the lamp cover cover. In this case, the center member F2 is joined to, for example, the upper or lower side of the lamp cover frame member F3.

[0043] In addition, although the present embodiment has been described in terms of the front module F including the lamp cover frame member F3, this is not limited to this. For example, the front module may be formed from the lamp cover F1 and the center member F2, excluding the lamp cover frame member F3. In this case, for example, the injection unit 10BC may be eliminated, and the injection units 10A and 10B may be arranged opposite each other. In this case, when molding one front module F, the order in which the lamp cover F1 and the center member F2 are injection molded may vary.

[0044] Furthermore, the arrangement of the injection unit 10 is not limited to the arrangement described in this embodiment. For example, the injection unit 10B may be arranged diagonally with respect to the mold opening / closing direction X so as to be able to inject into the runner 226, or may be arranged above the fixed platen 22 so as to perform injection from above. This also applies to the injection units 10A and 10C.

[0045] <Second embodiment> 6 is a diagram illustrating the configuration of an injection molding apparatus and a method for manufacturing a vehicle module according to this embodiment. For ease of understanding, only the lamp cover frame member F3 is shown hatched in FIG.

[0046] The injection molding apparatus 1A according to this embodiment differs from the injection molding apparatus 1 according to the first embodiment in that the third cavity for first molding the lamp cover frame member F3 when molding one front module F is defined only by the movable mold 242 and the intermediate mold 265. The injection molding apparatus 1A also differs from the injection molding apparatus 1 according to the first embodiment in that the first and second cavities for later molding the lamp cover F1 and the center member F2 when molding one front module F are defined by the fixed mold 222, the intermediate mold 265, and the lamp cover frame member F3. In other words, the first and second cavities are defined by dividing the space defined between the fixed mold 222 and the intermediate mold 265 by the lamp cover frame member F3. The injection molding apparatus 1A according to this embodiment also differs from the injection molding apparatus 1 according to the first embodiment in that a pair of ejector devices 70 are provided on the rotary table 263. As a modified example of the second embodiment, the lamp cover frame member F3 may be molded in a cavity defined only by the fixed mold 222 and the intermediate mold 265, but in any case, in the second embodiment, the lamp cover frame member F3 is molded first.

[0047] The operation of the injection molding apparatus 1A according to this embodiment will be described. As shown in Fig. 6(a), first, the lamp cover frame member F3 is held by the intermediate mold 265 on the movable mold 242 side. The method for achieving this state will be described later. Next, as shown in Fig. 6(b), the rotating plate 263 of the intermediate plate 26 is rotated 180 degrees, and the intermediate mold 265 holding the lamp cover frame member F3 is opposed to the fixed mold 222 so that they can be mated, that is, directly facing each other.

[0048] After the rotation, as shown in Fig. 6(c), the movable platen 24 and the intermediate platen 26 are moved in the mold closing direction, i.e., toward the fixed platen 22, and the mold clamping unit 20 enters a mold closing state. In the mold closing state, mold clamping is performed. After mold clamping, the injection units 10A to 10C inject molten resin into each cavity through the runners 224, 226, 244 and the gates corresponding to each runner.

[0049] Molten resin flows into the first and second cavities by injection from the injection units 10A and 10B through the runners 224, 226 and the gates corresponding to each runner, and the lamp cover F1 and center member F2 are joined to the lamp cover frame member F3 held in the intermediate mold 265 to form an integrated unit, thereby obtaining the front module F. Meanwhile, molten resin flows into the third cavity by injection from the injection unit 10C through the runner 244 and the gate, and a new lamp cover frame member F3 is molded.

[0050] After the front module F has been cooled for a predetermined period of time, the movable platen 24 and intermediate platen 26 are moved back to their original positions, i.e., in the mold opening direction, and the mold clamping unit 20 enters the mold opening state. After the mold clamping unit 20 enters the mold opening state, as shown in FIG. 6(d), the ejector pins of the ejector unit 70 are moved forward and protrude from the cavity surface of the intermediate mold 265, thereby releasing the front module F. After the front module F is released, the injection molding apparatus 1A enters a state in which the lamp cover frame member F3 is held by the intermediate mold 265 on the movable mold 242 side, similar to the state shown in FIG. 6(a). In other words, at the beginning of the device operation, only the injection unit 10C injects resin into the runner 244 and gate, as shown in FIG. 6(c).

[0051] According to the present embodiment described above, the lamp cover frame member F3 is molded before the lamp cover F1 and the center member F2, that is, the lamp cover F1 can be molded after the lamp cover frame member F3. Therefore, compared to the first embodiment in which the lamp cover F1 is molded first, the possibility of the lamp cover F1 being damaged when the primarily molded lamp cover F1 is re-fitted can be reduced.

[0052] Furthermore, since the center member F2 can be molded later, it is not impossible to perform in-mold painting in the fixed mold 222 and the intermediate mold 265. According to this embodiment, even if the intermediate mold 265 is on the rear surface side of the front module F, the ejector device 70 is provided on the turntable 263 on the intermediate mold 265 side or on the intermediate mold 265 itself, so that the ejector pins of the ejector device 70 can contact the rear surface of the front module F, thereby preventing the ejector pins from protruding the front surface of the front module F from leaving protrusion marks on the surface. In this embodiment, the lamp cover frame member F3 is shaped to fit into the rear surface side of the lamp cover F1. Therefore, the intermediate mold 265 may be formed to have a mold structure suitable for the front module F being on the rear surface side when mounted on a vehicle.

[0053] <Third embodiment> 7 is a diagram illustrating the configuration of an injection molding apparatus and a method for manufacturing a vehicle module according to this embodiment. For ease of understanding, the lamp cover F1, center member F2, and lamp cover frame member F3 are shown with different hatching in FIG.

[0054] The injection molding apparatus 1B according to this embodiment differs from the injection molding apparatus 1 according to the first embodiment in that an injection device 10B is disposed on the movable mold 242 side, and a second cavity for molding the center member F2 is defined by the movable mold 242 and an intermediate mold 265 including a core 266, which will be described later. Therefore, a runner 246 and a gate (see FIG. 7(e)) that can communicate with the second cavity are formed to allow resin for molding the center member F2 to flow into the movable platen 24 and the movable mold 242.

[0055] Furthermore, it differs from the injection molding apparatus 1 according to the first embodiment in that the third cavity for molding the lamp cover frame member F3 is defined by the lamp cover F1, the center member F2, the movable mold 242, and the intermediate mold 265.

[0056] Furthermore, the center member F2 according to this embodiment has a shape in which a portion thereof is recessed into the rear surface of the lamp cover frame member F3 (see FIGS. 7(c) and 7(d)). Specifically, both lateral ends of the center member F2 are extended to cover a portion of the periphery of the lamp cover F1, allowing the lamp cover F1 to be recessed into approximately the center of the extended portion. Therefore, the center member F2 according to this embodiment is formed with a runner and a gate through which the molten resin injected to form the lamp cover frame member F3 passes.

[0057] In order to make the extended portion of the center member F2 extend into the rear surface of the lamp cover frame member F3, each portion of the intermediate mold 265 where the lamp cover F1 is positioned is provided with a core 266 that can move freely in the mold opening and closing direction, enabling injection molding using the core-back method.

[0058] The operation of the injection molding apparatus 1B according to this embodiment will now be described. As shown in FIG. 7(a), first, the intermediate mold 265 on the fixed mold 222 side, specifically the core 266, is retracted and held in a core-back state, with the previously molded lamp cover F1 held on the core 266, and the previously molded center member F2 is held on the movable mold 242. The method for achieving this state will be described later. Next, as shown in FIG. 7(b), the rotating platen 263 of the intermediate platen 26 is rotated 180 degrees, and the intermediate mold 265 holding the lamp cover F1 is brought into opposition to the movable mold 242, i.e., directly facing, so that they can be mated.

[0059] After the rotation, as shown in FIG. 7(c), the movable platen 24 and the intermediate platen 26 are moved in the mold closing direction, i.e., toward the fixed platen 22, and the mold clamping device 20 enters a mold closing state. Then, a third cavity is formed from the cavity surface of the movable mold 244, the center member f2, the cavity surface of the intermediate mold 265, and the lamp cover F1. At this time, the core 266 of the intermediate mold 265 located on the fixed platen 22 side is cored back and moved to the movable mold 242 side, and remains housed within the intermediate mold 265. Next, mold clamping is performed in the mold closing state. After mold clamping, molten resin is injected into the cavity by the injection unit 10C via the runner 244 and the gate.

[0060] Molten resin flows into the third cavity by injection through the runner 244 and gate by the injection device 10C, and the lamp cover frame member F3 is joined to the lamp cover F1 and center member F2 held in each mold, forming a single unit, thereby obtaining the front module F.

[0061] After injection, the front module F is cooled for a predetermined time, and as shown in Figure 7(d), the movable platen 24 is moved to its original position, that is, in the mold opening direction, and the movable mold 242 and the intermediate mold 265 are in a mold open state. In this mold open state, the front module F is held by the movable mold 242. At this time, the ejector pins of the ejector unit 70 are moved in the forward direction and protrude from the cavity surface of the movable mold 242, thereby releasing the front module F. In addition, the core 266 in the core-backed state of the intermediate mold 265 located on the movable mold 242 side has its core-back released, that is, it is moved toward the movable mold 242 and is in a protruding state.

[0062] After the front module F is released from the mold, the injection molding apparatus 1 moves the movable platen 24 and the rotary platen 263 in the mold closing direction, i.e., the movable platen 24 moves toward the opposing intermediate mold 265, causing the mold clamping unit 20 to enter the mold closing state, as shown in FIG. 7(e). Mold clamping is performed in the mold closing state. Thereafter, the injection unit 10A and the injection unit 10B inject molten resin into the first and second cavities through the runners 224, 226 and the gates corresponding to each runner. At this time, the core 266 of the intermediate mold 265 located on the movable mold 242 side has its core back released and is maintained in an advanced state.

[0063] The lamp cover F1 is molded on the fixed mold 222 side by injection of molten resin into the first cavity by the injection unit 10A via the runner 224 and the gate. At this time, the core 266 of the intermediate mold 265 is retracted, and the first cavity surface is formed by at least the front surface of the retracted core 266 and the fixed mold 222. Meanwhile, the center member F2 is molded on the movable mold 242 side by injection of molten resin into the second cavity by the injection unit 10B via the runner 246 and the gate. At this time, the core 266 of the intermediate mold 265 is advanced, and the second cavity surface is formed by at least the front surface of the advanced core 266 and the movable mold 242. This makes it possible to mold the portion of the center member F2 located on the back surface of the lamp cover frame member F3 into a shape that follows the front shape of the core 266.

[0064] After the lamp cover F1 and the center member F2 are injected, these vehicle components are cooled for a predetermined time. After cooling, the mold clamping unit 20 enters the mold open state, and the injection molding apparatus 1B enters the state shown in Figure 7(a), with the lamp cover F1 held by the intermediate mold 265 on the fixed mold 222 side and the center member F2 held by the movable mold 242. In other words, at the beginning of the apparatus operation, the injection units 10A and 10B first inject molten resin into each cavity via the runners 224 and 246, as shown in Figure 7(e).

[0065] According to the present embodiment described above, the lamp cover F1 is first molded on the fixed platen 22 side, and the center member F2 is simultaneously molded on the movable platen 24 side. The lamp cover F1 is then moved to the movable platen 24 side and re-clamped, allowing the lamp cover frame member F3 to be formed later. This molding process allows the center member F2 to be shaped so that it fits into the rear surface of the lamp cover frame member F3. While the present embodiment describes molding the lamp cover F1 on the fixed platen 22 side and molding the center member F2 on the movable platen 24 side simultaneously, this is not limiting. For example, the lamp cover F1 may be molded first with a time lag, as shown in FIG. 7(d). Note that the phrase "simultaneously with molding" in the above means that each molding is performed during a single clamping operation. This also includes cases where the timing of injection from each injection unit 10A, 10B, the timing of mold opening of the fixed mold 222 and the intermediate mold 265, and the timing of mold opening of the movable mold 242 and the intermediate mold 265 are different from each other.

[0066] <Fourth embodiment> 8 is a diagram illustrating the configuration of an injection molding apparatus and a method for manufacturing a vehicle module according to this embodiment. For ease of understanding, the center member F2 and the lamp cover frame member F3 are shown with different hatching in FIG.

[0067] The injection molding apparatus 1C according to this embodiment differs from the injection molding apparatus 1 according to the first embodiment in that the front module F is molded by inserting a center member molded by another molding apparatus. Therefore, the injection molding apparatus 1C according to this embodiment does not include the injection apparatus 10B. Examples of other molding apparatuses include an injection molding apparatus different from the injection apparatus 10 included in the injection molding apparatus 1C, and a press molding machine capable of molding the center member F2 by compression molding. The other molding apparatuses also include those that are equipped, either internally or externally, with a painting apparatus for painting the center member or a plating apparatus for plating the center member.

[0068] The operation of the injection molding apparatus 1C according to this embodiment will be described. As shown in Fig. 8(a), first, the lamp cover F1 is held by the intermediate mold 265 on the fixed mold 222 side. The method for achieving this state will be described later. Next, as shown in Fig. 8(b), the rotating plate 263 of the intermediate platen 26 is rotated 180 degrees, and the intermediate mold 265 holding the lamp cover F1 is opposed to, or directly facing, the movable mold 242 so that they can be mated.

[0069] After rotation, the center member F2 molded by another molding device is inserted into an appropriate position in the intermediate mold 265 holding the lamp cover F1. That is, the center member F2 is attached to the cavity surface that defines the second cavity of the intermediate mold 265. After insertion, as shown in FIG. 8(c), the movable platen 24 and intermediate platen 26 are moved in the mold closing direction, that is, toward the fixed platen 22, and the mold clamping device 20 enters the mold closing state. In the mold closing state, mold clamping is performed. Then, a third cavity is formed by at least one of the lamp cover F1, center member F2, movable mold 242, and cavity surface of the intermediate mold 265. After mold clamping, molten resin is injected into the third cavity by the injection units 10A and 10C through the runners 224 and 244 and the gates corresponding to each runner.

[0070] Molten resin flows into the third cavity by injection through the runner 244 and gate by the injection device 10C, and the lamp cover frame member F3 is joined to the lamp cover F1 and center member F2 held in the intermediate mold 265 to form an integral unit, thereby obtaining the front module F. Meanwhile, resin flows into the first cavity by injection through the runner 224 and gate by the injection device 10A, and a new lamp cover F1 is molded.

[0071] After injection, the front module F and the new lamp cover F1 are cooled for a predetermined time. After cooling, as shown in FIG. 8(d), the movable platen 24 and intermediate platen 26 are moved to their original positions, that is, in the mold opening direction. At this time, the front module F is held by the movable mold 242 and released from the mold. At this time, the ejector pins of the pair of ejector devices 70 are moved forward and protrude from the cavity surface of the movable mold 242, releasing the front module F from the cavity surface. In other words, the mold opening between the fixed mold 222 and the intermediate mold 265 is also performed at approximately the same time as the mold opening between the movable mold 242 and the intermediate mold 265, and the injection molding apparatus 10C returns to the state shown in FIG. 8(a).

[0072] According to the present embodiment described above, by molding the lamp cover F1 first and then inserting the center member F2, it is possible to mold the lamp cover frame member F3 later. Therefore, according to this embodiment, it is possible to obtain a front module F even if various vehicle components are inserted. By using such an insert, for example, it becomes possible to relatively easily apply painting or coating (plating, etc.) to the center member, which is expected to have the effect of improving the design of the front module F. Furthermore, even if the center member F2 is made of CFRP (fiber reinforced thermosetting resin), which is difficult to mold by injection molding, it can be easily molded by press molding, etc.

[0073] In this embodiment, the center member F2 is inserted after the turntable 263 has rotated, but it may be inserted before the rotation. Furthermore, the member to be inserted, such as the center member, is not limited to a thermoplastic resin, and may be a member made of, for example, a thermosetting resin. In this case, the member may be joined to the lamp cover frame member F3, etc., using, for example, a laser.

[0074] Furthermore, the center member F2 may be inserted into the movable mold 242. In this case, as shown in Figures 8(c) and 8(d), even if the size of the center member F2 is such that it partially overlaps the lamp cover F1, a third cavity for molding the lamp cover frame member F3 can be formed between the lamp cover F1 on the intermediate mold 265 side and the center member F2 on the movable mold 242 side. Therefore, since there is no need to use the core-back method, it is possible to avoid increasing the complexity of various molds such as the movable mold 242 and the intermediate mold 265, and in some cases it is possible to achieve a reduction in mold costs.

[0075] <Fifth embodiment> Fig. 9 is a diagram for explaining the configuration of an injection molding apparatus and a method for manufacturing a vehicle module according to this embodiment. Fig. 10 is a schematic diagram showing a vehicle module molded by the injection molding apparatus according to this embodiment. For ease of understanding, in Fig. 9, tail lamp cover R1 (hereinafter simply abbreviated as lamp cover R1) and tail lamp cover R2 (hereinafter simply abbreviated as lamp cover R2) are shown with different hatching. Fig. 10(a) also shows a schematic view of the vehicle module as seen from the surface, and Fig. 10(b) shows a schematic view of a portion of the vehicle module molded by the core-back method.

[0076] The injection molding apparatus 1D according to this embodiment differs from the injection molding apparatus 1 according to the first embodiment in that it molds a rear module as a vehicle module. The rear module, designated by the symbol R in Fig. 10, includes two lamp covers R1 made of colored resin that cover tail lamps to be incorporated into the vehicle, two lamp covers R2 made of transparent or translucent resin that also cover the tail lamps, and a long center member R3 that is joined to the lamp covers R1 and / or R2, and these are integrated into one unit. Note that, as necessary, protrusions with bolt holes for fixing the rear module F to the vehicle are provided around the center member R3 and other components of the rear module.

[0077] For this reason, the injection unit 10A of the injection molding apparatus 1D according to this embodiment injects colored resin for molding the lamp cover R1, while the injection unit 10C injects transparent resin for molding the lamp cover R2, and the injection unit 10B injects resin for molding the center member R3.

[0078] The colored resin for the lamp cover R1 is, for example, red. The tail lamp may include a small lamp, a brake lamp, a back lamp, etc., and the lamp covers R1 and R2 may constitute covers for any two of these.

[0079] In this embodiment, the outer side of each of the lateral ends of the lamp cover R2 is recessed into the rear surface of the lamp cover R1, and the other end is recessed into the rear surface of the center member R3. To achieve this shape, this embodiment uses core-back molding using a core 247, which will be described later. Specifically, the core 247, which is configured to be movable in the mold opening / closing direction, is provided in the movable mold 242, thereby realizing the shape of the center member R3 described above.

[0080] In the injection molding apparatus 1D according to this embodiment, the injection device 10A is disposed on the movable mold 242 side, and a fourth cavity for molding the lamp cover R1 is defined by the movable mold 242 including the core 247 and the intermediate mold 265. Therefore, a runner 248 and a gate (see FIG. 9(c)) that can communicate with the fourth cavity for injecting molten resin for molding the lamp cover R1 into the movable platen 24 and the movable mold 242 are formed.

[0081] Furthermore, a fifth cavity for molding the lamp cover R2 is defined by the movable mold 242 including the core 247, the intermediate mold 265, and the center member R3. Therefore, the movable platen 24 and the movable mold 242 are formed with a runner 249 and a gate (see FIG. 9(d)) that can communicate with the fifth cavity into which molten resin for molding the lamp cover R2 flows.

[0082] Additionally, a sixth cavity for molding the center member R3 is defined by the fixed mold 222 and the intermediate mold 265. Therefore, the fixed platen 22 and the fixed mold 222 are formed with a runner 227 and a gate (see FIG. 9(c)) that can communicate with the sixth cavity and through which molten resin for molding the center member R3 flows.

[0083] The operation of the injection molding apparatus 1D according to this embodiment will now be described. As shown in FIG. 9(a), first, the center member R3 molded during the previous clamping operation is held by the intermediate mold 265 on the fixed mold 222 side. The method for achieving this state will be described later. Next, as shown in FIG. 9(b), the rotating platen 263 of the intermediate platen 26 is rotated 180 degrees, and the intermediate mold 265 holding the center member R3 is brought into opposition to, i.e., directly facing, the movable mold 242 so that they can be mated.

[0084] After the rotation, as shown in Figure 9(c), the movable platen 24 and the intermediate platen 26 are moved in the mold closing direction, i.e., toward the fixed platen 22, and the mold clamping unit 20 enters a mold closing state. Mold clamping is performed in the mold closing state. After mold clamping, the injection unit 10A injects molten resin into the fourth cavity through the runner 248 and the gate. At this time, the core 247 of the movable mold 242 is maintained in an uncored state, i.e., protruding toward the intermediate mold 265.

[0085] The lamp cover R1 is molded by injection of molten resin into the fourth cavity via the runner 248 and the gate by the injection device 10A. Similarly, the molten resin is injected into the sixth cavity via the runner 227 and the gate by the injection device 10B. The center member R3 is molded by injection of molten resin into the sixth cavity via the runner 227 and the gate by the injection device 10B.

[0086] After the lamp cover R1 and the center member R3 are injected, these vehicle components are cooled for a predetermined time. After cooling, the mold clamping state is temporarily released, and as shown in FIG. 9(d), the core 247 of the movable mold 242 is returned to its core-back state, that is, moved to the movable mold 242 side and housed therein (see FIG. 10(b)). This core-back creates a fifth cavity from the wall surface of the lamp cover R1, the front surface of the core 247, the wall surface of the center member R3, and the cavity surface of the intermediate mold 265. Then, with the next injection, part of the lamp cover R2 can be inserted into the back surface of part of the lamp cover R1 and part of the center member R3.

[0087] Next, the mold is clamped again, and resin flows into the fifth cavity by injection from injection device 10C through runner 249 and the gate, and the lamp cover R2 is integrally molded with the lamp cover R1 and the center member R3, thereby obtaining the rear module R.

[0088] After the injection of the rear module R, the rear module R is cooled for a predetermined time. When cooling is completed, as shown in Fig. 9(e), the movable mold 242 is moved to its original position, that is, in the mold opening direction, and the mold clamping unit 20 enters the mold open state. In this mold open state, the ejector unit 70 is moved in the mold clamping direction and ejects the rear module R from the cavity surface of the movable mold 242, thereby releasing the core 247 of the movable mold 242, which is in a core-back state, and the core 247 is released and moved forward toward the intermediate mold 256.

[0089] After the rear module R is demolded and removed, the injection molding apparatus 1D is in a state in which the center member R3, which was molded in parallel at the same time as the mold was clamped, is held in the intermediate mold 265 on the fixed mold 222 side, as shown in Fig. 9(a). In other words, explaining the molding procedure for one molded product, initially, only the injection of resin into the runner 224 and gate by the injection unit 10B is performed, as shown in Fig. 9(c).

[0090] According to the present embodiment described above, it is possible to mold the rear module R as a vehicle module. In addition, it is possible to mold a part of the lamp cover R2 so that it fits into the rear surface side of a part of the lamp cover R1 and / or the center member R3.

[0091] In the present embodiment, the rear module R has the lamp covers R1 and R2 connected in the longitudinal direction, but the lamp covers R1 and R2 may also be connected in the vertical direction. Furthermore, the area where the lamp covers R1 and R2 are attached by joining or the like may be the area where the license plate is attached to the vehicle or the area that is covered by the back door, i.e., not visible from the outside.

[0092] In addition, in this embodiment, the two lamp covers R1, R2 are described as being joined together, but this is not limited to this. The lamp covers R1, R2 may be adjacent to each other via a resin window serving as the center member R3, and not be directly joined. For example, one such rear module shape is one in which the lamp covers R1, R2 are integrally molded below both longitudinal ends of the resin window.

[0093] In a specific manufacturing method, a resin window is injection-molded using either the fixed mold 222 or the movable mold 242 and the opposing intermediate mold 265, and the back door is held by the intermediate mold 265. Then, the turntable 263 is rotated, and the intermediate mold 265 is positioned directly opposite the other of the fixed mold 222 or the movable mold 242. After the facing, the lamp cover R1 is injection-molded using the other mold and the intermediate mold 265 that holds the resin window. After molding the lamp cover R1, the core 247 is core-backed, and the lamp cover R2 is injection-molded using the other mold and the intermediate mold 265 that holds the resin window and the lamp cover R1. The order of molding the lamp cover R1 and the lamp cover R2 may be reversed. This allows for concealing gate marks when the lamp cover R2 is located on the vehicle surface. Alternatively, the lamp covers R1 and R2 may be injection-molded first, and then the lamp covers R1 and R2 may be held in the intermediate mold 265 while the turntable 263 is rotated, and the resin window is injection-molded. Furthermore, since the resin window is thicker than the lamp cover, it may be inserted after being formed by another molding device such as a press.

[0094] <First application example> In the fifth embodiment described above, a method for manufacturing a rear module R including a center member as a vehicle module has been described, but the present invention is not limited to this. A rear module including a tailgate may also be manufactured. For example, the following four methods can be considered for manufacturing a rear module having a tailgate using a resin such as a thermoplastic resin or a thermosetting resin containing reinforced fiber instead of the center member R3.

[0095] (1st plan) A rear module having a back door is manufactured by adapting the manufacturing method according to the first embodiment described with reference to Figure 5. Specifically, the back door and the lamp cover R1 are injection molded using the fixed mold 222 and the opposing intermediate mold 265, and these are held in the intermediate mold 265. The turntable 263 is then rotated to bring the intermediate mold 265 directly into opposition to the movable mold 242. After the facing is complete, the lamp cover R2 is injection molded using the fixed mold 222 and the intermediate mold 265 that holds the back door and lamp cover R1. A rear module having a back door can be obtained by this series of manufacturing processes.

[0096] (2nd plan) A rear module having a tailgate is manufactured by adapting the manufacturing method according to the fifth embodiment described with reference to FIG. 9 . Specifically, the tailgate is injection-molded using the fixed mold 222 and the opposing intermediate mold 265, and the intermediate mold 265 holds the tailgate. The turntable 263 is then rotated to position the intermediate mold 265 directly facing the movable mold 242. After the two are directly opposed to each other, the lamp cover R1 is injection-molded using the movable mold 242 and the intermediate mold 265 that holds the tailgate. After molding the lamp cover R1, the core 247 is returned to its original position, and with the lamp cover R1 interposed, the lamp cover R2 is injection-molded using the movable mold 242 and the intermediate mold 265 that holds the tailgate. This series of manufacturing steps allows for the production of a rear module having a tailgate. The order of molding the lamp cover R1 and the lamp cover R2 may be reversed. By reversing the order, gate marks left by the mold can be hidden when the lamp cover R2 is located on the surface of the vehicle.

[0097] (3rd plan) A rear module having a tailgate is manufactured using the manufacturing method according to the fourth embodiment described with reference to FIG. 8, i.e., a manufacturing method using an insert. Specifically, the tailgate is molded in advance using another molding device. Next, the molded tailgate is inserted into the fixed mold 222 or the intermediate mold 265 facing it. After insertion, the lamp cover R2 is injection molded between the fixed mold 222 and the intermediate mold 265 with the tailgate interposed therebetween. Thereafter, the turntable 263 is rotated to directly face the intermediate mold 265 to the movable mold 242. After facing directly, the lamp cover R1 is injection molded between the movable mold 242 and the intermediate mold 265 that holds the tailgate and lamp cover R2. A rear module having a tailgate can be obtained by this series of manufacturing methods.

[0098] (4th plan) As in the third proposal, a rear module with a tailgate is manufactured using an insert manufacturing method. Specifically, the tailgate is molded in advance using another molding device. Next, either the lamp cover R1 or the lamp cover R2 is injection-molded using the fixed mold 222 and the opposing intermediate mold 265, and the molded lamp cover is held in the intermediate mold 265. The turntable 263 is then rotated to directly face the intermediate mold 265 toward the movable mold 242. After this, the tailgate molded in either the movable mold 242 or the intermediate mold 265 is inserted prior to mold closing. After the insertion, the other of the lamp cover R1 or the lamp cover R2 is injection-molded using the movable mold 242 and the intermediate mold 265, with the tailgate interposed therebetween. This series of manufacturing steps results in a rear module with a tailgate. In this case, the tailgate and one of the lamp covers are joined by the other lamp cover.

[0099] <Second application example> Furthermore, a rear module including a tailgate may further include a resin window. For example, a method for manufacturing such a rear module involves a core-back process using two types of cores in the movable mold 242. Specifically, a resin window is injection-molded using the fixed mold 222 and an intermediate mold 265 facing it and held in the intermediate mold 265. After the turntable 263 rotates, a tailgate is injection-molded using the movable mold 242 and the intermediate mold 265 holding the resin window. After molding the tailgate, one of the cores is core-backed, and with the resin window and tailgate interposed, a lamp cover R1 is injection-molded using the movable mold 242 and the intermediate mold 265. After molding the lamp cover R1, the other core is core-backed, and with the resin window, tailgate, and lamp cover R1 interposed, a lamp cover R2 is injection-molded using the movable mold 242 and the intermediate mold 265. This series of manufacturing processes allows for the production of a rear module including the tailgate, resin window, and lamp covers R1 and R2.

[0100] Alternatively, the rear module may be obtained by inserting and core-backing. Specifically, the rear door is molded in advance using another molding device. Next, the molded rear door is inserted into either the fixed mold 222 or the opposing intermediate mold 265. After the insertion, a resin window is injection-molded between the fixed mold 222 and the opposing intermediate mold 265 and held in the intermediate mold 265. After the turntable 263 rotates, the lamp cover R1 is injection-molded between the movable mold 242 and the intermediate mold 265 with the rear door and resin window interposed. After the lamp cover R1 is molded, the core 247 is core-backed, and the lamp cover R2 is injection-molded between the movable mold 242 and the intermediate mold 265 with the rear door, resin window, and lamp cover R1 interposed. This series of manufacturing processes allows the rear module including the rear door, resin window, and lamp covers R1 and R2 to be obtained.

[0101] In the first to fifth embodiments and the first and second application examples, a front module F and a rear module R have been described as examples of vehicle modules to be manufactured. However, this is not limited to this. An instrument panel integrated with a decorative surface member or a transparent cover for a meter can also be manufactured using the injection molding apparatus and manufacturing method according to the present invention. Furthermore, a front module or a rear module integrated with a bumper portion (including a bumper beam portion in some cases) can also be manufactured using the injection molding apparatus and manufacturing method according to the present invention.

[0102] In the first to fifth embodiments and the first and second application examples, the injection molding apparatus has been described as having three injection units, some of which are arranged facing each other, and including an intermediate platen 26. However, any of the injection units may contact the mold from the side or above, perpendicular to the mold opening / closing direction. Alternatively, a vehicle module may be manufactured using a so-called rotary molding machine in which multiple injection units are arranged side by side rather than facing each other, and a rotary table is attached with two molds instead of the intermediate platen 26 and capable of opening and closing the mold. In this case, the molds attached to the rotary table are formed so as to be matable with the molds corresponding to the individual injection units, i.e., two molds corresponding to the fixed mold and the movable mold.

[0103] Although embodiments of the invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the inventions and their equivalents as set forth in the claims. [Explanation of symbols]

[0104] 1,1A~1D injection molding equipment 10,10A~10C injection device 30 Control device (molding control unit) 222 Fixed mold (first mold, second mold) 224 Movable mold (first mold, second mold) 265 Intermediate mold F Front module (vehicle module) F1 Lamp cover (first vehicle member, second vehicle member, headlamp cover) F2 Center member (first vehicle member, second vehicle member, connecting member) F3 Lamp cover frame member (first vehicle member, second vehicle member) R Rear module (vehicle module) R1, R2 Lamp cover (first vehicle member, second vehicle member, tail lamp cover) R3 Center member (first vehicle member, second vehicle member, connecting member)

Claims

1. A method for manufacturing a vehicle module including at least first and second vehicle members using an injection molding apparatus having a first mold, a second mold, and an intermediate mold positioned between the first and second molds and matable with each other, comprising: one of the first and second vehicle components includes a vehicle lamp cover; injection molding a first vehicle component using the first mold and the intermediate mold; In a state where the first vehicle member is held on the first mold side of the intermediate mold and the mold is opened, the intermediate mold is rotated so that the first vehicle member faces the second mold, Using the second mold and the intermediate mold, the second vehicle member is injection molded so that the second vehicle member is joined to the first vehicle member. A method for manufacturing a vehicle module.

2. Prior to the rotation of the intermediate mold, Using the first mold and the intermediate mold, a third vehicle component different from the first and second vehicle components is further injection molded, thereby holding the third vehicle component together with the first vehicle component in the intermediate mold. A method for manufacturing the vehicle module according to claim 1.

3. Using the second mold and the intermediate mold, the second vehicle component and a third vehicle component different from the first and second vehicle components are injection molded. A method for manufacturing the vehicle module according to claim 1.

4. Prior to the rotation of the intermediate mold, the first vehicle component is injection molded using the first mold and the intermediate mold, and a third vehicle component different from the first and second vehicle components is injection molded using the second mold and the intermediate mold; rotating the intermediate mold while the first vehicle member is held by the intermediate mold and the third vehicle member is held by the second mold; Using the second mold and the intermediate mold, the second vehicle member is injection molded so that the second vehicle member is joined to the first and third vehicle members. A method for manufacturing the vehicle module according to claim 1.

5. Prior to the injection molding of the second vehicle component, a third vehicle component molded by another molding device and different from the first and second vehicle components is inserted into either the second mold or the intermediate mold. A method for manufacturing the vehicle module according to claim 1.

6. the first vehicle member is a connecting member, the second vehicle component is a lamp cover having optical transparency, the third vehicle component is a lamp cover or a frame member of a lamp cover that has a different light transmittance or material from the second vehicle component, After the intermediate mold is rotated, either the second vehicle member or the third vehicle member is injection molded onto the first vehicle member, and then the other of the second and third vehicle members is injection molded using a core-back method. A method for manufacturing the vehicle module according to claim 3.

7. the vehicle module is a front module member, the lamp cover is a headlamp cover, One of the first and second vehicle members is the headlamp cover, and the other is either a frame member of the headlamp cover or a connecting member connecting the frame member. A method for manufacturing the vehicle module according to any one of claims 1 to 6.

8. the vehicle module is a rear module member, One of the first and second vehicle members is a first tail lamp cover, and the other is either a second tail lamp cover made of a material different from the first tail lamp cover, or a connecting member that connects either the first or second tail lamp cover. A method for manufacturing the vehicle module according to any one of claims 1 to 6.

9. A vehicle module including at least first and second vehicle components manufactured using an injection molding apparatus having a first mold, a second mold, and an intermediate mold that can be molded with each of the first and second molds, one of the first and second vehicle components includes a vehicle lamp cover; In a state where a first vehicle component injection-molded using the first mold and the intermediate mold is held on the first mold side of the intermediate mold and opened, the intermediate mold is rotated so that the first vehicle component faces the second mold, and the second vehicle component is injection-molded using the second mold and the intermediate mold so that the second vehicle component is joined to the first vehicle component. Vehicle module.

10. 1. An injection molding apparatus for manufacturing a vehicle module including at least first and second vehicle components, a first mold; a second mold; an intermediate mold that is positioned between the first and second molds and can be matched with each other, and that can rotate to face the first vehicle component toward the second mold when a first vehicle component injection molded using the first mold and the intermediate mold is held on the first mold side and molded open; a molding control unit that uses the second mold and the intermediate mold to injection-mold the second vehicle component so that the second vehicle component is joined to the first vehicle component; Equipped with One of the first and second vehicle components includes a vehicle lamp cover. Injection molding equipment.

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