Manufacturing method for metal parts

Abstract

The objective is to suppress the retention of metal fragments in the hole when removing protrusions at the opening edge of a hole that only opens at the tip of a metal component using electrical discharge machining, compared to when the machining fluid is stagnant in the hole. [Solution] The method for manufacturing a metal part comprises the steps of: immersing a metal member, which has one hole extending in one direction with its tip opening on one surface and having a projection on the edge of the opening, and another hole connected to the base end of the first hole with at least one end opening on the other surface, in a processing fluid so that one surface faces a discharge electrode; and discharging electricity between the one surface and the discharge electrode while the processing fluid is flowing.

Description

Technical Field

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[0001] The present invention relates to a method for manufacturing metal parts.

Background Art

[0002] The deburring device described in Patent Document 1 includes a master electrode having the same or similar shape over the entire machining surface of a workpiece where burrs occur at a plurality of locations, a servo feed device that gives a machining feed to the master electrode in a gap facing the workpiece, a pulse power source that applies pulses to the facing gap to repeat discharges, and an inspection device that determines the completion of machining and removal of all burrs on the workpiece based on a signal detected from the pulse supply circuit of the pulse power source or from the facing gap.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Protrusions (so-called burrs) may occur at the opening edges of holes formed in metal members. In such a case, the protrusions are removed by immersing the metal member and the discharge electrode in a machining fluid and discharging between the metal member and the discharge electrode.

[0005] Here, when protrusions occur at the opening edge of a hole that is open only at the tip, the machining fluid may stay in the hole. In this way, when the protrusions are removed by discharging between the metal member and the discharge electrode with the machining fluid staying in the hole, the protrusions (the protrusions removed from the metal member) may remain in the hole as metal pieces. <000003θ> The problem of the present disclosure is to suppress the remaining of metal pieces in the hole when removing the protrusions at the opening edge of a hole that is open only at the tip of a metal member by electrical discharge machining, as compared with the case where the machining fluid stays in the hole. [Means for solving the problem]

[0007] A method for manufacturing a metal part according to a first aspect of the present disclosure is characterized by comprising the steps of: immersing a metal member having one hole extending in one direction with its tip opening on one surface and having a projection on the edge of the opening, and another hole connected to the base end of the first hole and having at least one end opening on the other surface, in a processing fluid such that one surface faces a discharge electrode; and discharging a discharge between the one surface and the discharge electrode while the processing fluid is flowing.

[0008] A method for manufacturing a metal part according to a second aspect of the present disclosure is characterized in that, in the method for manufacturing a metal part according to the first aspect, the other hole formed in the metal member immersed in the processing fluid extends in a cross direction intersecting the one direction and is also open on the opposite side of the metal member that faces the opposite side to the other side.

[0009] A third aspect of the present disclosure is a method for manufacturing a metal part, characterized in that, in the method for manufacturing a metal part described in the second aspect, the metal member immersed in the processing fluid has a plurality of holes arranged in the intersecting direction, and the base ends of the plurality of holes are connected to one other hole.

[0010] A method for manufacturing a metal part according to a fourth aspect of this disclosure is characterized in that, in the method for manufacturing a metal part according to the first aspect, in the step of discharging a discharge between the surface and the discharge electrode, the processing fluid is supplied to the region between the surface and the discharge electrode.

[0011] A fifth aspect of the present disclosure is a method for manufacturing a metal part, the same as the method for manufacturing a metal part described in the fourth aspect, wherein the other hole formed in the metal member immersed in the processing fluid extends in an intersecting direction that intersects with respect to the one direction, both ends of the other hole are open in the intersecting direction, the metal member immersed in the processing fluid has a plurality of the one hole arranged in the intersecting direction, the base ends of the plurality of the one hole are connected to one of the other holes, and in the step of discharging between the one surface and the discharge electrode, the processing fluid is supplied to the region from the central portion of the area in which the one hole is formed in the metal member in the intersecting direction, and the processing fluid is recovered from the outside of the metal member in the intersecting direction.

[0012] A method for manufacturing a metal part according to a sixth aspect of this disclosure is characterized in that, in the method for manufacturing a metal part according to the fifth aspect, in the step of discharging between the surface and the discharge electrode, the processing fluid is recovered from both outer sides of the metal member in the intersecting direction. [Effects of the Invention]

[0013] According to the manufacturing method for metal parts of the first aspect of this disclosure, when removing a projection on the opening edge of a single hole in which only the tip of the metal member is open by electrical discharge machining, it is possible to suppress the retention of metal fragments in the single hole compared to when the processing fluid is stagnant in the single hole.

[0014] According to the manufacturing method of a metal part of a second aspect of this disclosure, it is possible to suppress the retention of metal fragments in one hole compared to the case where only one of the other holes is open.

[0015] According to the manufacturing method of a metal part of the third aspect of this disclosure, the number of other holes can be reduced compared to the case in which multiple holes are formed in each of a plurality of other holes.

[0016] According to the manufacturing method of a metal part of the fourth aspect of this disclosure, the flow rate of the processing fluid flowing from the tip to the base of one hole can be increased compared to the case in which the processing fluid is supplied toward the discharge electrode.

[0017] According to the manufacturing method for metal parts of the fifth aspect of this disclosure, the flow rate of the processing fluid flowing from the tip to the base of one hole can be increased compared to the case where the area to which the processing fluid is supplied and the area to which the processing fluid is collected are the same.

[0018] According to the manufacturing method for metal parts of the sixth aspect of this disclosure, the flow rate of the processing fluid flowing from the tip to the base of one hole can be increased compared to the case in which the processing fluid is collected only from the outside of one of the metal members in the intersecting direction. [Brief explanation of the drawing]

[0019] [Figure 1] This is a schematic diagram showing an image forming apparatus equipped with an image reading device having a light-shielding portion formed using a metal part manufactured by a metal part manufacturing method according to the embodiment of this disclosure. [Figure 2] This is a schematic diagram showing an image reading unit equipped with an image reading device having a light-shielding portion formed using a metal part manufactured by the method for manufacturing metal parts according to the embodiment of this disclosure. [Figure 3] This is a perspective view showing an image reading device equipped with a light-shielding portion formed using a metal part manufactured by the metal part manufacturing method according to the embodiment of this disclosure. [Figure 4] This is an overall perspective view showing an image reading device equipped with a light-shielding portion formed using a metal part manufactured by the metal part manufacturing method according to the embodiment of this disclosure. [Figure 5] This is an enlarged cross-sectional view showing an image reading device equipped with a light-shielding portion formed using a metal part manufactured by a metal part manufacturing method according to an embodiment of this disclosure. [Figure 6] This is an operation diagram showing the operation of an image reading unit equipped with an image reading device having a light-shielding portion formed using a metal part manufactured by the method for manufacturing metal parts according to the embodiment of this disclosure. [Figure 7]A perspective view showing an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure. [Figure 8] An exploded perspective view showing an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure. [Figure 9] A cross-sectional view of an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure, taken along a direction orthogonal to the longitudinal direction. [Figure 10] A cross-sectional view of an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure, taken along the longitudinal direction. [Figure 11] An enlarged cross-sectional view of an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure, taken along a direction orthogonal to the longitudinal direction. [Figure 12] An enlarged perspective view showing a microlens array provided in an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure. [Figure 13] An exploded perspective view showing a condensing portion provided in an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure. [Figure 14] An enlarged plan view showing a microlens array provided in an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure. [Figure 15] A perspective view showing a condensing portion provided in an image reading apparatus including a light shielding portion formed using a metal part manufactured by a method for manufacturing a metal part according to an embodiment of the present disclosure. [Figure 16] ​ [Figure 17] This is an enlarged plan view showing a portion of a light-shielding portion formed using a metal part manufactured by the manufacturing method of a metal part according to the embodiment of this disclosure. [Figure 18] (A)(B) are a plan view and a side view showing the entire light-shielding portion formed using a metal part manufactured by the manufacturing method of a metal part according to the embodiment of this disclosure. [Figure 19] This is a cross-sectional view showing a mold using a metal part manufactured by a metal part manufacturing method according to an embodiment of the present disclosure. [Figure 20] This is a cross-sectional view showing a mold using a metal part manufactured by a metal part manufacturing method according to an embodiment of the present disclosure. [Figure 21] This is an enlarged cross-sectional view showing a mold using a metal part manufactured by a metal part manufacturing method according to an embodiment of the present disclosure. [Figure 22] This is a plan view showing the entire mold using a metal part manufactured by the metal part manufacturing method according to the embodiment of this disclosure. [Figure 23] This is a perspective view showing an ejector pin provided in a mold using a metal part manufactured by a metal part manufacturing method according to an embodiment of the present disclosure. [Figure 24] (A)(B)(C)(D) These are process diagrams showing the process of opening a mold from a clamped state to an open state using a metal part manufactured by a method for manufacturing a metal part according to the embodiment of this disclosure. [Figure 25] (A)(B)(C)(D) These are process diagrams showing the process of opening a mold from a clamped state to an open state using a metal part manufactured by a method for manufacturing a metal part according to the embodiment of this disclosure. [Figure 26] This is a perspective view showing a metal part manufactured by a metal part manufacturing method according to an embodiment of this disclosure. [Figure 27] This is a perspective view showing a metal member used in a method for manufacturing a metal part according to an embodiment of this disclosure. [Figure 28] This is a front view showing an electrical discharge machining apparatus used in a method for manufacturing metal parts according to an embodiment of the present disclosure. [Figure 29] This is a side view showing an electrical discharge machining apparatus used in a method for manufacturing metal parts according to an embodiment of the present disclosure. [Figure 30] This is a schematic diagram showing the direction in which the processing fluid flows inside a metal member in a method for manufacturing a metal part according to an embodiment of the present disclosure. [Figure 31] This is a perspective view showing a metal member relating to a comparative form of a metal member used in a method for manufacturing a metal part according to an embodiment of this disclosure. [Figure 32] This is a front view showing a modified form of an electrical discharge machining apparatus used in a method for manufacturing metal parts according to the embodiments of this disclosure. [Figure 33] This is a side view showing a modified form of an electrical discharge machining apparatus used in a method for manufacturing metal parts according to the embodiments of this disclosure. [Figure 34] This is a perspective view showing a modified form of an electrical discharge machining apparatus used in a method for manufacturing metal parts according to the embodiments of this disclosure. [Modes for carrying out the invention]

[0020] An example of a method for manufacturing a metal part according to the embodiment of this disclosure will be described. An example of a mold using an insert, which is a metal part manufactured by the method for manufacturing a metal part, and an example of a light-shielding part formed by this mold will also be described. Furthermore, an example of an image reading device equipped with a light-shielding member formed by joining multiple light-shielding parts, and an example of an image forming apparatus equipped with the image reading device will also be described.

[0021] The image forming apparatus, image reading apparatus, light-shielding member, mold, metal component insert, and method of manufacturing the metal component will be described in this order. In the diagram, arrow H indicates the vertical direction of the apparatus, arrow W indicates the horizontal direction of the apparatus width, and arrow D indicates the horizontal direction of the apparatus depth. The vertical direction, the horizontal direction of the apparatus width, and the horizontal direction of the apparatus are orthogonal to each other. The vertical direction of the apparatus may also be referred to as the vertical direction, the horizontal direction of the apparatus depth as the depth direction, and the horizontal direction of the apparatus width as the width direction.

[0022] (Overall configuration of the image forming apparatus) As shown in Figure 1, the image forming apparatus 10 is equipped with a storage unit 14, a transport unit 16, an image forming unit 20, and an image reading unit 60 in that order, from bottom to top.

[0023] The storage unit 14 houses the sheet member P, which is to be used as a recording medium. The transport unit 16 transports the sheet member P housed in the storage unit 14. The image forming unit 20 forms an image on the sheet member P transported by the transport unit 16. The image reading unit 60 reads the image formed on the original document G.

[0024] [Storage Section 14] The storage section 14 is equipped with a storage member 26 that can be pulled out from the housing 10a of the image forming apparatus 10 toward the front in the depth direction of the apparatus. Sheet members P are loaded onto this storage member 26. Furthermore, the storage section 14 is equipped with a delivery roll 30 that sends the uppermost sheet member P loaded onto the storage member 26 to the sheet member P transport path 28.

[0025] [Conveying section 16] The transport unit 16 is equipped with multiple transport rolls 32 that transport the sheet material P along the transport path 28.

[0026] [Image forming unit 20] The image forming unit 20 is equipped with four image forming units 18Y, 18M, 18C, and 18K, which are yellow (Y), magenta (M), cyan (C), and black (K). In the following description, Y, M, C, and K may be omitted when it is not necessary to distinguish between them.

[0027] Each color image forming unit 18 is detachable from the housing 10a. Each color image forming unit 18 is equipped with an image holder 36, a charging roll 38, an exposure device 42, and a developing device 40. The charging roll 38 charges the surface of the image holder 36. The exposure device 42 irradiates the charged image holder 36 with exposure light. The developing device 40 develops the electrostatic latent image formed by the exposure of the charged image holder 36 by the exposure device 42 and visualizes it as a toner image.

[0028] The image forming unit 20 is also equipped with a transfer belt 22, a primary transfer roll 44, a secondary transfer roll 46, and a fixing device 50. The transfer belt 22 is an endless belt that circulates in the direction of arrow A in the figure. The primary transfer roll 44 transfers the toner images formed by the image forming units 18 of each color to the transfer belt 22. The secondary transfer roll 46 transfers the toner images transferred to the transfer belt 22 to the sheet member P. The fixing device 50 heats and pressurizes the sheet member P on which the toner images have been transferred to fix the toner images to the sheet member P.

[0029] [Image reading unit 60] As shown in Figure 2, the image reading unit 60 comprises a first transparent plate 62 (a so-called platen glass) and a second transparent plate 72. The first transparent plate 62 is on which a document G is placed when reading an image of a single document G. The second transparent plate 72 is positioned on one side (to the left in the figure) of the first transparent plate 62 in the width direction of the device. The first transparent plate 62 and the second transparent plate 72 are fitted into the upper part of the housing 60a of the image reading unit 60.

[0030] Above the first transparent plate 62 and the second transparent plate 72, an opening / closing cover 66 is positioned to open and close the first transparent plate 62 and the second transparent plate 72. Inside the opening / closing cover 66 is a transport device 64 (a so-called ADF device). The transport device 64 transports multiple documents G along the transport path 70 inside the opening / closing cover 66, passing them through the document reading position R above the second transparent plate 72.

[0031] Furthermore, the housing 60a is equipped with an image reading device 100 that reads the image of the original document G placed on the first transparent plate 62 and the image of the original document G transported to the document reading position R by the transport device 64. In addition, the image reading unit 60 is equipped with a drive device 74 that drives the image reading device 100 in the width direction of the device. The image reading device 100 is an example of an optical device. Details of the image reading device 100 will be described later.

[0032] As shown in Figures 2 and 3, the drive unit 74 comprises a shaft 76 and a sliding member 78. The shaft 76 extends in the width direction of the device (the direction of movement of the image reading device 100). The sliding member 78 is attached to the lower surface of the housing 114 of the image reading device 100 and is slidably supported on the shaft 76.

[0033] Furthermore, the drive unit 74 includes a motor 80, a drive pulley 84, a driven pulley 86, and an endless belt 82. The drive pulley 84 is attached to one end of the shaft 76 and is rotationally driven by the driving force transmitted from the motor 80. The driven pulley 86 is attached to the other end of the shaft 76 and rotates in a driven manner. The endless belt 82 is endless and is wound around the drive pulley 84 and the driven pulley 86.

[0034] As shown in Figure 4, the sliding member 78 is attached to the lower surface of the housing 114, towards the center in the depth direction of the device. As shown in Figure 5, the sliding member 78 has a slit 78a and a sliding surface 78b extending in the vertical direction. A portion of the endless belt 82 is fitted into the slit 78a. The sliding surface 78b is semicircular when viewed from the width direction of the device and slides against the shaft 76.

[0035] Furthermore, as shown in Figure 4, a pair of support parts 90 that support both ends of the shaft 76 from below are integrally formed with the housing 60a.

[0036] In this configuration, the case in which the image of the original document G being transported by the transport device 64 is read will be described. The image reading device 100 receives the driving force of the motor 80 via the endless belt 82 and moves to the transport reading position at the end in the width direction of the device, as shown in Figure 6, and stops. The image reading device 100 then reads the image of the original document G being transported by the transport device 64.

[0037] Next, we will explain the case of reading the image of the original document G placed on the first transparent plate 62. As shown in Figure 2, the image reading device 100, positioned at the reading start position (solid line in the figure), moves in the width direction of the device along the first transparent plate 62 toward the reading end position (dotted line in the figure) while reading the image of the original document G. In this way, the image reading device 100 reads the image of the original document G placed on the first transparent plate 62.

[0038] (Image reading device 100) Next, the image reading device 100 will be described in detail. The image reading device 100 shown in Figure 7 is configured to read the image formed on the original document G using a known CIS (Contact Image Sensor) method.

[0039] The image reading device 100, as shown in Figure 8, comprises a light-receiving substrate 102, a wiring cable 104, a rigid substrate 106, and a light-emitting element 128. Furthermore, the image reading device 100 comprises a light guide 110 (a so-called light guide), a light-collecting unit 112, a housing 114, and a glass plate 122. The light-receiving substrate 102 is an example of a substrate.

[0040] A pair of wiring cables 104 are provided and connected to the light-receiving substrate 102. The rigid substrate 106 is connected to each of the wiring cables 104. The light-emitting element 128 is mounted on the rigid substrate 106. A pair of light guides 110 are provided and are cylindrical in shape. The light-collecting unit 112 collects the reflected light reflected from the original document G. The glass plate 122 covers the top surface of the housing 114.

[0041] [Cabinet 114] As shown in Figure 8, the housing 114 is box-shaped and extends in the depth direction of the device. As shown in Figure 9, the housing 114 has a light guide housing section 114a, a lens housing section 114b, and a substrate housing section 114c.

[0042] A pair of light guide housing sections 114a are provided, each housing a pair of light guides 110. A lens housing section 114b is formed between the pair of light guide housing sections 114a and houses a light concentrator 112. A pair of substrate housing sections 114c, shown in Figure 10, are provided so as to sandwich the light guide housing section 114a from the depth direction of the device and house a rigid substrate 106.

[0043] -Light guide housing section 114a- As shown in Figures 9 and 10, the light guide housings 114a are formed in pairs, side by side in the width direction of the device. Each light guide housing 114a extends in the depth direction of the device. Furthermore, the cross-sections of each light guide housing 114a intersecting in the longitudinal direction are semicircular with an open top.

[0044] -Lens housing 114b- As shown in Figure 9, the lens housing portion 114b is formed between a pair of light guide housing portions 114a in the device width direction. Furthermore, the lens housing portion 114b penetrates a part of the housing 114 in the vertical direction. The lens housing portion 114b has a pair of protrusions 116 that support the device width direction end of the lower surface of the light concentrating portion 112.

[0045] - Circuit board housing section 114c - As shown in Figure 10, a pair of substrate housing sections 114c are formed on the rear and front sides in the depth direction of the device relative to the light guide housing section 114a. Specifically, the substrate housing section 114c is formed between the walls 119 at both ends of the housing 114 in the depth direction of the device and the light guide housing section 114a.

[0046] -others- As shown in Figures 9 and 10, a stepped portion 115 is formed on the upper part of the housing 114, which supports the edge of the glass plate 122 from below. Also, as shown in Figure 9, a counterbore surface 117 is formed on the lower part of the housing 114, which is in contact with the upper surface of the light-receiving substrate 102.

[0047] [Light guide 110] As shown in Figure 9, the light guide 110 is housed in the light guide housing section 114a of the housing 114. The light guide 110 is formed from a transparent material (for example, acrylic resin) and is cylindrical in shape, extending in the depth direction of the device. The light guides 110 are arranged in pairs side by side in the width direction of the device.

[0048] The light guide 110 is fixed to the housing 114 by a fixing part (not shown) in the longitudinal direction, so that both ends in the longitudinal direction can extend and retract in the depth direction of the device. The end face 110a of the light guide 110 and the LED 128, which is located inside the wall portion 119 of the housing 114, are separated in the depth direction of the device (see Figure 10).

[0049] In Figure 10, the end face 110a of the light guide 110 and the LED 128 are shown to be in contact in the depth direction of the device. However, in reality, the end face 110a of the light guide 110 and the LED 128 are separated so that they do not come into contact even if the light guide 110 extends in the depth direction of the device due to temperature changes. In other words, the gap between the end face 110a of the light guide 110 and the LED 128 is set to a dimension that prevents contact between the end face 110a and the LED 128 even if the light guide 110 extends in the depth direction of the device due to temperature changes.

[0050] Furthermore, the light guide 110 is provided with a reflective member (not shown) along its longitudinal direction that causes light incident from the end face 110a of the light guide 110 and traveling in the longitudinal direction of the light guide 110 to be emitted upward (in the direction of arrow B in Figure 9) toward the light concentrating section 112.

[0051] [Light-gathering unit 112] As shown in Figure 9, the light-gathering unit 112 is housed in the lens housing 114b of the housing 114. The light-gathering unit 112 is shaped like a rectangular parallelepiped extending in the depth direction of the device. This light-gathering unit 112 comprises a light-shielding member 150 and a pair of microlens arrays 152. The pair of microlens arrays 152 is an example of an optical element.

[0052] Furthermore, the light-gathering section 112 is supported at its lower end in the device width direction by a projection 116 on the housing 114 and is fixed to the housing 114 by fixing means (not shown). In this state, both ends of the light-gathering section 112 in the longitudinal direction and the inner surface of the wall portion 119 of the housing 114 are separated in the device depth direction (see Figure 10). The light-gathering section 112 will be described in detail later.

[0053] [Light receiving substrate 102] As shown in Figure 9, the light-receiving substrate 102 has its thickness oriented vertically and is positioned at the lower end of the housing 114. The light-receiving substrate 102 is fixed to the housing 114 by fixing means (not shown) with its upper surface in contact with the counterbore surface 117 of the housing 114.

[0054] The light-receiving substrate 102 is rectangular in shape, extending in the depth direction of the device when viewed from above. Multiple light-receiving elements 126 are mounted on the upper surface of the light-receiving substrate 102, arranged in the depth direction of the device. Furthermore, the light-receiving elements 126 mounted on the light-receiving substrate 102 face the light-collecting unit 112 in the vertical direction (see Figure 9).

[0055] Here, implementation refers to attaching something to an object in order to realize some function. In this embodiment, in order to make the light-receiving element 126 capable of receiving light, the light-receiving element 126 is attached to the light-receiving substrate 102 using fixing means such as solder. The light-receiving element 126 is an example of an optical element.

[0056] [Wiring cable 104] The wiring cable 104 is provided in pairs and is a so-called flexible flat cable with its base ends connected to both ends of the light-receiving substrate 102 in the depth direction of the device, as shown in Figure 8. The base end of one wiring cable 104 is connected to the rear end (left side in the figure) of the light-receiving substrate 102 in the depth direction of the device. The base end of the other wiring cable 104 is connected to the front end (right side in the figure) of the light-receiving substrate 102 in the depth direction of the device.

[0057] [Rigid substrate 106] A pair of rigid substrates 106 are provided and connected to the ends of the wiring cables 104, as shown in Figure 8. The rigid substrates 106 are rectangular in shape, extending in the width direction of the device when viewed from the depth direction of the device. Two LEDs 128 (hereinafter referred to as "light-emitting elements 128") are mounted on one side of each rigid substrate 106 (opposite sides to each other), aligned in the width direction of the device.

[0058] Then, as shown in Figure 10, the rigid substrate 106 is housed in the substrate housing portion 114c of the housing 114, facing the end face 110a of the light guide 110.

[0059] [Glass plate 122] As shown in Figure 8, the glass plate 122 has its thickness in the vertical direction and is rectangular in shape, extending in the depth direction of the device when viewed from above. As shown in Figure 9, the glass plate 122 is fixed to the housing 114 by fixing means (not shown) with the edge of the glass plate 122 in contact with the stepped portion 115 of the housing 114. The glass plate 122 is positioned to cover the top surface of the housing 114.

[0060] (Operation of the image reading device 100) Next, the operation of the image reading device 100 will be explained. The light-emitting element 128 shown in Figure 10 irradiates light onto the end face 110a of the light guide 110. Furthermore, the light guide 110 guides the light incident from the end face 110a in the longitudinal direction of the light guide 110. Then, as shown in Figure 9, the light guide 110 emits the light reflected by the reflective member upwards towards the light-collecting section 112 (in the direction of arrow B in the figure).

[0061] Furthermore, the light-collecting unit 112 emits light from the light guide 110 and irradiates the original document G, guiding (collecting) the reflected light reflected from the original document G to the light-receiving element 126. In this way, the light-receiving element 126 receives the reflected light reflected from the original document G and converts it into an electrical signal.

[0062] (Configuration of the light-gathering unit 112) Next, the light-gathering section 112 will be described. As shown in Figures 9 and 11, the light-gathering section 112 comprises a light-shielding member 150 and a pair of microlens arrays 152 (hereinafter referred to as "lens array 152"). The light-shielding member 150, one microlens array 152, and the other microlens array 152 are arranged in this order from the glass plate 122 side to the light-receiving substrate 102 side. The lens array 152 is an example of an optical component.

[0063] [Microlens array 152] The microlens array 152 is integrally formed using polymethyl methacrylate (PMMA), a transparent resin material, and is shaped like a rectangular parallelepiped extending in the depth direction of the device.

[0064] The microlens array 152 has an upper surface 152a, a lower surface 152b, and projections 154 and 156, as shown in Figures 12 and 13. The upper surface 152a is rectangular in shape, facing upward and extending in the depth direction of the device when viewed from above. The lower surface 152b is rectangular in shape, facing downward and extending in the depth direction of the device when viewed from below. The projections 154 are formed on both ends of the upper surface 152a in the width direction of the device and protrude upward in the depth direction of the device. The projections 156 are formed on both ends of the lower surface 152b in the width direction of the device and protrude downward in the depth direction of the device.

[0065] Furthermore, multiple lens surfaces 158 are formed on the upper surface 152a and the lower surface 152b, respectively, protruding from the upper surface 152a or the lower surface 152b. The amount of protrusion of these lens surfaces 158 is made smaller compared to the amount of protrusion of the projections 154 and 156.

[0066] These lens surfaces 158 are arranged in two rows in a staggered pattern along the depth direction of the device (see Figure 14). "Staggered pattern" means "alternating." Furthermore, in the vertical direction of the device, the lens surface 158 formed on the upper surface 152a and the lens surface 158 formed on the lower surface 152b are positioned at the same, equivalent, or similar location. That is, the lens axis (optical axis) of the lens surface 158 formed on the upper surface 152a and the lens axis (optical axis) of the lens surface 158 formed on the lower surface 152b overlap. This pair of lens surfaces 158 forms a microlens 164. Note that the microlens 164 is an example of a lens.

[0067] [Lens Array 152] As shown in Figures 13 and 15, the tops of the protrusions 154 and 156 are brought together so that the optical axis of the microlens 164 of one microlens array 152 aligns with the optical axis of the microlens 164 of the other microlens array 152. Then, using a fixing member such as an adhesive (not shown), each (pair) of microlens arrays 152 is fixed in this state to form the lens array 152.

[0068] [Light-shielding member 150] As shown in Figures 16 and 17, the light-shielding member 150 extends in the depth direction of the device. The light-shielding member 150 has a plurality of cylindrical through-holes 170 that penetrate through the device in the vertical direction. This light-shielding member 150 is a component that reduces light in a direction inclined with respect to the axial direction of the through-holes 170 by allowing light to pass through the through-holes 170.

[0069] The through-holes 170 are arranged in two rows in a staggered pattern along the depth direction of the device. Specifically, the through-holes 170 are arranged along the depth direction of the device at the same, equal, or similar intervals. Furthermore, there are two rows of through-holes 170 arranged along the depth direction of the device. In addition, the positions of the through-holes 170 in one row and the through-holes 170 in the other row are offset in the depth direction of the device. In other words, two rows of through-holes 170 are formed in the width direction of the device, extending in the vertical direction of the device and aligned in the depth direction of the device.

[0070] As a result, the multiple through-holes 170 viewed from above overlap with the multiple microlenses 164 (see Figure 12) formed on the lens array 152 viewed from above. In this embodiment, as an example, the length of the light-shielding member 150 in the device depth direction (L1 in Figure 16) is 336 [mm], and the diameter of the through-holes 170 (D1 in Figure 17) is 0.45 [mm]. The spacing (pitch) of the through-holes 170 in the device depth direction is 0.55 [mm].

[0071] The light-shielding member 150 is constructed by joining together six light-shielding sections 160, which extend in the depth direction of the device, using an adhesive or the like, while they are arranged in the depth direction of the device.

[0072] -Light-shielding section 160- The light-shielding portion 160 is integrally molded from a black resin material (for example, acrylonitrile-butadiene-styrene copolymer resin (ABS resin)). In this embodiment, as an example, the length of the light-shielding portion 160 in the device depth direction (L2 in Figure 18(A)) shown in Figure 18(A) is 56 [mm]. Also, the thickness of the light-shielding portion 160 in the vertical direction (T1 in Figure 18(B)) is 5 [mm].

[0073] Furthermore, as shown in Figure 18(A), a through hole 170 is formed in the light-shielding portion 160. In addition, two semicircular grooves 172 extending in the vertical direction of the device are formed at both ends of the light-shielding portion 160 in the depth direction of the device. When the light-shielding portions 160 are joined together in the depth direction of the device, adjacent grooves 172 face each other, forming one through hole 170.

[0074] Furthermore, the light-shielding section 160 has a base section 160a and an overhanging section 160b. The base section 160a extends in the depth direction of the device. The overhanging sections 160b are positioned on the central and both ends of the base section 160a in the depth direction of the device, and protrude from the base section 160a on both sides in the width direction of the device. As a result, the side surface of the light-shielding section 160 facing the width direction of the device is not a single plane, but is composed of multiple planes positioned at different locations in the width direction of the device.

[0075] The base section 160a has a parallelogram shape that extends in the depth direction of the device when viewed from the top or bottom direction of the device. The overhang section 160b has a parallelogram shape that extends in the depth direction of the device when viewed from the top or bottom direction of the device, with one corner chamfered. The lengths of the pair of overhang sections 160b located at both ends are the same in the depth direction of the device. The length of the overhang section 160b located in the center is twice the length of the overhang sections 160b located at both ends in the depth direction of the device.

[0076] In this embodiment, as an example, the width of the base portion 160a (W1 in Figure 18(A)) is 2 [mm], and the width of the protruding portion 160b (W2 in Figure 18(A)) is 2.6 [mm].

[0077] In this configuration, the reflected light reflected from the original document G passes through the through-hole 170 formed in the light-shielding member 150 and enters the microlens 164 of one of the microlens arrays 152, as shown in Figure 9.

[0078] Among the reflected light passing through the through-hole 170, light tilted relative to the vertical direction of the device may be reflected once on the inner surface of the through-hole 170 in the light-shielding section 160 and enter the microlens 164. However, light entering the through-hole 170 at a large tilt angle undergoes repeated reflections on the inner surface of the through-hole 170, resulting in repeated attenuation of light intensity. Therefore, even if it enters the microlens 164, the light intensity becomes negligible. In this way, the incidence of large stray light on the microlens 164 is suppressed.

[0079] Then, light incident on a microlens 164 of one microlens array 152 is emitted from that microlens 164 of the one microlens array 152. Furthermore, the emitted light is incident on a microlens 164 of the other microlens array 152. Light incident on a microlens 164 of the other microlens array 152 is emitted from that microlens 164 of the other microlens array 152 and is focused (concentrated) on the light-receiving element 126.

[0080] (Mold 200 for light-shielding part 160) Next, the mold 200 used to form the light-shielding portion 160 will be described using Figures 19 to 34. The light-shielding portion 160 is formed by injection molding. Furthermore, the mold 200 will be described using the direction of the light-shielding portion 160 being formed.

[0081] As shown in Figure 20, the mold 200 comprises a pair of molds. Specifically, the mold 200 comprises a fixed mold 210 and a movable mold 260. The fixed mold 210 and the movable mold 260, when clamped together, form a molding space 200a (a so-called cavity) extending in the depth direction of the apparatus for molding the light-shielding portion 160, as shown in Figure 19. Figure 19 is a cross-sectional view of the movable mold 260 cut in a direction perpendicular to the vertical direction of the apparatus.

[0082] As shown in Figure 20, the fixed type 210 and the movable type 260 are divided vertically in the device, with the movable type 260 positioned below the fixed type 210.

[0083] [Fixed type 210] As shown in Figures 20 and 21, the fixed type 210 has a rectangular cross-section when viewed from the depth direction of the device. Specifically, it is rectangular in shape extending in the width direction of the device, and the lower surface 210a of the fixed type 210 is the mating surface with the movable type 260.

[0084] Here, in the fixed mold 210, the portion facing the molding space 200a in the vertical direction of the apparatus is designated as an insert 300. The insert 300 is a rectangular parallelepiped extending in the depth direction, as shown in Figure 26. The insert 300 is an example of a metal part.

[0085] As shown in Figures 21 and 26, the insert 300 has multiple vertical holes 302 and one horizontal hole 310. The vertical holes 302 extend in the vertical direction of the device. The ends of the vertical holes 302 open on one surface 300a of the insert 300 that faces the molding space 200a. In other words, only the ends of the vertical holes 302 of the insert 300 are open. Here, "the hole is open" means that the hole is open to the outside of the insert from the outer surface of the insert. The vertical holes 302 are an example of one type of hole, and the vertical direction of the device is an example of one direction.

[0086] Furthermore, the vertical holes 302 are arranged in a staggered pattern in two rows along the depth direction of the apparatus. Specifically, the vertical holes 302 are arranged along the depth direction of the apparatus at the same, equal, or similar intervals. The base ends of multiple cylindrical pins 214 (see Figure 21) that extend in the vertical direction of the apparatus and cross the molding space 200a are attached to the vertical holes 302. These pins 214 form through holes 170 (see Figure 17).

[0087] The horizontal hole 310 extends in the depth direction, and its inner diameter is larger than that of the vertical hole 302. The horizontal hole 310 opens to the end face 300b facing the front in the depth direction and to the end face 300c facing the back in the depth direction of the nested part 300. In other words, the horizontal hole 310 opens to the end face 300b and to the end face 300c facing the opposite side of the end face 300b. The horizontal hole 310 is an example of another hole, and the depth direction is an example of an intersecting direction. Also, the end face 300b is an example of another face, and the end face 300c is an example of an opposite face.

[0088] Furthermore, the horizontal holes 310 are connected to the base ends of all the vertical holes 302. In other words, all the vertical holes 302 are connected via a single horizontal hole 310. The manufacturing method of the nesting element 300 will be described in detail later.

[0089] As mentioned above, the pins 214 shown in Figure 21 are attached to the vertical holes 302. Therefore, the pins 214 are arranged in a staggered pattern in two rows along the depth direction of the device. Specifically, the pins 214 are arranged along the depth direction of the device at the same, equal, or similar intervals. In addition, two rows (cylindrical rows) of pins 214 arranged along the depth direction of the device are provided in the width direction of the device. Furthermore, the positions of the pins 214 in one row and the pins 214 in the other row are offset in the depth direction of the device.

[0090] More specifically, when viewed from above or below the device, the centers of two adjacent pins 214 in one row and the center of one pin 214 in the other row that is closest to both of those two pins 214 are arranged to form the vertices of an equilateral triangle. Similarly, when viewed from above or below the device, the centers of two adjacent pins 214 in the other row and the center of one pin 214 in the one row that is closest to both of those two pins 214 are arranged to form the vertices of an equilateral triangle.

[0091] Furthermore, in the cross-sectional views such as Figures 20 and 21, the pins 214 in one row are shown aligned in the width direction of the device so that the relative positions of the pins 214 in the width direction of the device can be easily determined.

[0092] Furthermore, as shown in Figure 20, the fixed mold 210 has a spool 216 through which the molten resin flows. The spool 216 is one of the passages for sending the molten resin into the molding space 200a. Note that the molten resin (molten resin) is sometimes referred to as molten resin.

[0093] Specifically, the spool 216 extends in the vertical direction of the apparatus and penetrates the fixed mold 210. Furthermore, the spool 216 is positioned on only one side of the molding space 200a in the width direction of the apparatus. The spools 216 are formed in pairs, aligned in the depth direction of the apparatus, as shown in Figure 22.

[0094] [Movable type 260] The movable type 260 is a type that moves toward and away from the fixed type 210 (in the vertical direction of the device) by a driving mechanism (not shown). As shown in Figure 20, the movable type 260 has a rectangular cross-section when viewed from the depth direction of the device. Specifically, it is rectangular in the width direction of the device, and the upper surface 260a of the movable type 260 is the mating surface with the fixed type 210. Note that when viewed from the width direction of the device, the movable type 260 has a rectangular shape that extends in the depth direction of the device.

[0095] Here, in the movable mold 260, the part that faces the molding space 200a in the vertical direction of the apparatus is designated as an insert 350. The insert 350 is a rectangular parallelepiped extending in the depth direction, as shown in Figure 26. The insert 350 is an example of a metal part.

[0096] The insert 350 has multiple vertical holes 352 and one horizontal hole 360. The vertical holes 352 extend in the vertical direction of the device. The tip (upper end) of the vertical holes 352 opens on one side 350a of the insert 350 that faces the molding space 200a. In other words, only the tip of the vertical holes 352 of the insert 350 is open.

[0097] Furthermore, the vertical holes 352 are arranged in a staggered pattern in two rows along the depth direction of the device. Specifically, the vertical holes 352 are arranged along the depth direction of the device at the same, equal, or similar intervals. The tip of the pin 214 (see Figure 21) attached to the nesting 300 of the fixed type 210 is inserted into the vertical holes 352. The vertical hole 352 is an example of a single hole.

[0098] The horizontal hole 360 ​​extends in the depth direction, and its inner diameter is larger than that of the vertical hole 352. The horizontal hole 360 ​​opens to the end face 350b facing the front in the depth direction and to the end face 350c facing the back in the depth direction of the nesting part 350. In other words, the horizontal hole 360 ​​opens to the end face 350b and to the end face 350c facing the opposite side of the end face 350b. The horizontal hole 360 ​​is an example of another hole, the end face 350b is an example of another face, and the end face 350c is an example of the opposite face.

[0099] Furthermore, the horizontal holes 360 are connected to the base ends of all the vertical holes 352. In other words, all the vertical holes 352 are connected via a single horizontal hole 360. The manufacturing method of the nesting element 350 will be described in detail later.

[0100] -Runner 264- As shown in Figure 20, a runner 264 is formed between the upper surface 260a of the movable mold 260 and the lower surface 210a of the fixed mold 210 by making the upper surface 260a of the movable mold 260 concave. The runner 264 is located on only one side of the molding space 200a in the width direction of the apparatus and extends in the width direction of the apparatus. The runner 264 is one of the passages for feeding the molten resin into the molding space 200a and is designed to receive the molten resin that has flowed through the spool 216.

[0101] The runners 264 are formed in pairs, aligned in the depth direction of the apparatus, as shown in Figure 22. Specifically, the ends of the runners 264 are connected to one surface 262a of the movable mold 260, which faces the molding space 200a and forms the base portion 160a (see Figure 18). More specifically, the ends of the runners 264 are connected to the longitudinal central portion of one surface 262a.

[0102] Furthermore, in the fixed mold 210 and movable mold 260 in the clamped state, the portion of the runner 264 that connects to one surface 262a is designated as a supply port 266 (gate) for supplying molten resin to fill the molding space 200a.

[0103] -Exhaust space 270- As shown in Figure 20, a discharge space 270 (a so-called waste cavity) is formed between the upper surface 260a of the movable mold 260 and the lower surface 210a of the fixed mold 210 by making the upper surface 260a of the movable mold 260 concave. The discharge space 270 is located only on the other side of the molding space 200a in the width direction of the apparatus and extends in the width direction of the apparatus.

[0104] Furthermore, as shown in Figure 22, the discharge spaces 270 are formed in pairs, aligned in the depth direction of the apparatus. Specifically, the ends of the discharge spaces 270 are connected to the other surface 262b of the movable mold 260, which faces the molding space 200a and forms the base portion 160a (see Figure 18). More specifically, the ends of the discharge spaces 270 are connected to the longitudinal central portion of the other surface 262b. Thus, the discharge spaces 270 extending in the width direction of the apparatus are offset in the depth direction of the apparatus relative to the runner 264 extending in the width direction of the apparatus.

[0105] Furthermore, the portion of the discharge space 270 that connects to the other surface 262b is designated as an outlet 276 through which a portion of the molten resin discharged from the molding space 200a is discharged. As a result, the discharge space 270 is filled with the molten resin discharged from the outlet 276.

[0106] -Protruding pin- As shown in Figure 23, ejector pins 274 (so-called ejector pins) extending in the vertical direction of the device are provided below the runner 264 and the discharge space 270.

[0107] The ejector pin 274 is provided on the movable mold 260 and moves up and down to two positions, an ejector position and a retracted position, by a drive mechanism (not shown). Specifically, in the mold clamping (mold closing) state, the ejector pin 274 does not protrude from the surface forming the runner 264 and the discharge space 270 on the movable mold 260 (retracted position). After the mold opens, the ejector pin 274 pushes the solidified resin that has solidified in the discharge space 270 and the solidified resin that has solidified in the runner 264 from below. In this way, the ejector pin 274 demolds (releases) the solidified resin that has solidified in the molding space 200a and become the light-shielding portion 160, together with the solidified resin that has solidified in the runner 264 and the discharge space 270, from the movable mold 260. After demolding, the solidified resin that has hardened in the runner 264 is cut at a position corresponding to the supply port 266 (gate) (so-called gate cut), and the solidified resin that has hardened in the discharge space 270 is cut at a position corresponding to the discharge port 276. This completes the light-shielding section 160.

[0108] -Slide type- The movable mold 260 is provided with a sliding mold 280, as shown in Figure 22. The sliding mold 280 moves downward in the width direction of the apparatus as the clamped movable mold 260 moves downward relative to the fixed mold 210, moving away from the solidified resin that has filled and solidified in the molding space 200a. The sliding mold 280 has one surface 262c and the other surface 262d formed thereon to form the protruding portion 160b (see Figure 18).

[0109] Three slide molds 280 are arranged on one side of the molding space 200a in the width direction of the apparatus, and three slide molds 280 are arranged on the other side of the molding space 200a in the width direction of the apparatus. These six slide molds 280 differ in length in the depth direction of the apparatus, but otherwise have the same configuration.

[0110] In the area where the slide type 280 is positioned in the depth direction of the device, the movable type 260 comprises a main body type 278 having a nesting 350 and the slide type 280, as shown in Figure 24(A).

[0111] In this region, the cross-sectional shape of the main body type 278 is rectangular, extending in the width direction of the device. In other regions, the main body type 278 moves integrally, as shown in Figure 25(A).

[0112] The following provides a detailed explanation of the slide-type 280. As shown in Figure 24(A), the slide mold 280 has a lower surface 280a that contacts (slides) with the upper surface 278a of the main mold 278, and surfaces 262c and 262d that face the molding space 200a. Furthermore, the slide mold 280 has an inclined surface 280c formed on the opposite side from surfaces 262c and 262d, and which is inclined with respect to the vertical direction of the device.

[0113] Furthermore, the slide mold 280 has a side surface 280d that is positioned below the inclined surface 280c and faces outward in the width direction of the apparatus. In addition, projections 282 are formed on surfaces 262c and 262d that protrude into the molding space 200a.

[0114] Here, surface 262c is the surface facing the molding space 200a in the slide mold 280 located on one side in the width direction of the apparatus. Surface 262d is the surface facing the molding space 200a in the slide mold 280 located on the other side in the width direction of the apparatus (see Figure 22).

[0115] On the other hand, in the region where the slide mold 280 is arranged in the depth direction of the apparatus, the fixed mold 210 is provided with a corresponding mold 220 for the slide mold 280. The corresponding mold 220 has an inclined surface 220a that contacts the inclined surface 280c when the mold is clamped, and an opposing surface 220b that faces the side surface 280d with a gap between them when the mold is clamped. In this embodiment, since a total of six slide molds 280 are provided, a total of six corresponding molds 220 are also provided.

[0116] In this configuration, when the mold is clamped, a molding space 200a is formed between the fixed mold 210 and the movable mold 260, as shown in Figure 24(A). Molten resin is filled into the molding space 200a, and after the filled molten resin solidifies into solidified resin, the mold is opened.

[0117] During mold opening, as shown in Figure 24(B), the movable mold 260 moves downward relative to the fixed mold 210. The sliding mold 280 moves downward and also moves in the width direction of the apparatus so as to move away from the solidified resin. This sliding mold 280 is pressed in the width direction of the apparatus by a pressing means (not shown) so as to move away from the solidified resin.

[0118] Specifically, the slide mold 280 is constantly pulled by an elastic member such as a tension coil spring in a direction away from the solidified resin in the width direction of the apparatus. In other words, the three slide molds 280 positioned on one side of the molding space 200a, with surfaces 262c formed thereon, are constantly pulled by the elastic member in a direction away from the molding space 200a (upwards in Figure 22). The three slide molds 280 positioned on the other side of the molding space 200a, with surfaces 262d formed thereon, are constantly pulled by the elastic member in a direction away from the molding space 200a (downwards in Figure 22). As the inclined surface 280c of the slide mold 280 is pressed against the inclined surface 220a of the corresponding mold 220, the slide mold 280 moves downward while moving in the width direction of the apparatus.

[0119] As a result, the gap between the side surface 280d and the opposing surface 220b gradually decreases, and the side surface 280d of the slide mold 280 comes into contact with the opposing surface 220b of the corresponding mold 220. In this state, in the width direction of the apparatus, the projections 282 of the slide mold 280 overlap with the solidified resin. In other words, the projections 282 of the three slide molds 280 with surfaces 262c and the projections 282 of the three slide molds 280 with surfaces 262d are each inserted into recesses (undercuts) formed on the surfaces of the solidified resin facing the width direction of the apparatus. Therefore, the solidified resin moves downward as the movable mold 260 moves downward.

[0120] In other words, the solidified resin is prevented from remaining on the fixed mold 210 side while adhering to the pin 214 (the so-called "sticking phenomenon"). The recesses formed on the surface of the solidified resin facing the width direction of the device are formed in the solidified resin by the cooling and solidification of the molten resin around the protrusions 282 formed on the surface 262c of the slide mold 280, and there are a total of six such recesses.

[0121] As the movable type 260 moves further downward, the pin 214 attached to the fixed type 210 disengages from the solidified resin, as shown in Figure 24(C). Until the pin 214 disengages from the solidified resin, the side surface 280d of the slide type 280 and the opposing surface 220b of the corresponding type 220 are in contact (sliding). In other words, in the width direction of the device, the projection 282 of the slide type 280 overlaps with the solidified resin. Therefore, as the movable type 260 moves downward, the solidified resin moves downward, thus suppressing the above-mentioned sticking phenomenon.

[0122] As the movable type 260 moves further downward, the inclined surface 280c of the slide type 280 reaches the corner 220c at the lower end of the opposing surface 220b of the corresponding type 220, as shown in Figure 24(D). As the inclined surface 280c of the slide type 280 is pressed against the corner 220c of the corresponding type 220, the slide type 280 moves downward in a direction (orientation) that separates it from the solidified resin in the width direction of the device. Then, the projection 282 of the slide type 280 disengages from the recess formed in the solidified resin. In other words, in the width direction of the device, the projection 282 of the slide type 280 separates from the solidified resin.

[0123] (Method for molding the light-shielding portion 160) Next, a molding method for forming the light-shielding portion 160 by injection molding using the mold 200 will be described. When forming the light-shielding portion 160 by injection molding using the mold 200, the fixed mold 210 and the movable mold 260 are clamped together, as shown in Figures 24(A) and 25(A). The fixed mold 210 and the movable mold 260 form a molding space 200a. The tip of the pin 214 attached to the fixed mold 210 is inserted into the vertical hole 352 of the movable mold 260 (see Figure 21).

[0124] In this state, molten resin is poured into the molding space 200a from the supply port 266 shown in Figure 20, thereby filling the molding space 200a with molten resin. Specifically, molten resin is poured into the molding space 200a from only one side in the width direction of the apparatus, and the molding space 200a is filled with molten resin.

[0125] Furthermore, in the mold 200, the resin discharged from the outlet 276 through the molding space 200a fills the discharge space 270. In other words, in the mold 200, a portion of the molten resin filling the molding space 200a passes through the outlet 276 and fills the discharge space 270. Then, the molten resin filling each part cools and solidifies.

[0126] After the molten resin cools and solidifies into solid resin, the mold is opened. During mold opening, as shown in Figures 24(B) and 25(B), the movable mold 260 moves downward relative to the fixed mold 210. The sliding mold 280 shown in Figure 24(B) moves downward and also moves in the width direction of the apparatus so as to move away from the solidified resin.

[0127] Specifically, the slide mold 280 is pressed in the width direction of the apparatus by a pressing means (not shown) so as to move away from the solidified resin. Then, as the inclined surface 280c of the slide mold 280 is pressed against the inclined surface 220a of the corresponding mold 220, the slide mold 280 moves downward while moving in the width direction of the apparatus. Also, the side surface 280d of the slide mold 280 is in contact with the opposing surface 220b of the corresponding mold 220. In this state, the projection 282 of the slide mold 280 overlaps with the solidified resin in the width direction of the apparatus.

[0128] As the movable type 260 moves further downward, the pin 214 attached to the fixed type 210 disengages from the solidified resin, as shown in Figures 24(C) and 25(C). Until the pin 214 disengages from the solidified resin, the side surface 280d of the slide type 280 and the opposing surface 220b of the corresponding type 220 are in contact, as shown in Figure 24(C). In other words, in the width direction of the device, the projection 282 of the slide type 280 overlaps with the solidified resin.

[0129] As the movable type 260 moves further downward, the pin 214 attached to the fixed type 210 separates from the solidified resin, as shown in Figures 24(D) and 25(D). Also, the inclined surface 280c of the slide type 280, shown in Figure 24(C), reaches the corner 220c at the lower end of the opposing surface 220b of the corresponding type 220. As the inclined surface 280c of the slide type 280 is pressed against the corner 220c of the corresponding type 220, the slide type 280 moves downward while moving in the width direction of the device. Then, the projection 282 of the slide type 280 disengages from the solidified resin. In other words, in the width direction of the device, the projection 282 of the slide type 280 separates from the solidified resin.

[0130] In other words, because the mold 200 is equipped with a sliding mold 280, when the mold is opened, the solidified resin is prevented from sticking to the pins 214 of the fixed mold 210 and remaining on the fixed mold 210 side.

[0131] In this way, the mold 200 is opened. With the mold 200 open, the ejector pin 274 shown in Figure 23 moves upward and pushes from below the solidified resin that has solidified in the discharge space 270 and the solidified resin that has solidified in the runner 264, thereby demolding the solidified resin that has solidified in the molding space 200a.

[0132] Furthermore, post-processing removes the solidified resin that has solidified in the discharge space 270 and the solidified resin that has solidified in the runner 264, and the light-shielding portion 160 is formed.

[0133] In this case, in the mold 200, molten resin is poured into the molding space 200a from only one side in the width direction of the apparatus, so all the pins 214 curve in the same direction due to the resin pressure of the molten resin. Specifically, the pins 214 in one row curve so as to be convex to the other side in the width direction of the apparatus, and the pins 214 in the other row curve so as to be convex to the other side in the width direction of the apparatus. As a result, the thinning of the resin thickness between through holes 170 and other through holes 170 in the light-shielding portion 160 molded by the mold 200 is suppressed.

[0134] (Nested 300, 350) Next, the metal components 400 and 450 used to manufacture the inserts 300 and 350 will be described. Furthermore, the electrical discharge machining apparatus 600 used to manufacture the inserts 300 and 350 from the metal components 400 and 450, and the method for manufacturing the inserts 300 and 350 will be described.

[0135] [Metal components 400, 450] First, let's describe the metal members 400 and 450. As shown in Figure 27, the metal members 400 and 450 are rectangular parallelepipeds extending in the depth direction. The metal members 400 and 450 have vertical holes 302 and 352 and horizontal holes 310 and 360 formed therein. The vertical holes 302 and 352 are formed using a drill. Specifically, a drill rotated so that its axis of rotation is perpendicular to one surface 300a and 350a is inserted into the metal members 400 and 450 from one surface 300a and 350a to form the vertical holes 302 and 352. As a result, in the vertical holes 302 and 352, protrusions (burrs) 402 and 452 are generated on the opening edges 302a and 352a that open to one surface 300a and 350a. Here, a drill is a cutting tool made of a round steel bar with a spiral cutting edge and a chip relief groove.

[0136] [Electric discharge machining equipment 600] Next, we will describe the electrical discharge machining apparatus 600 used in the manufacturing method of the inserts 300 and 350. In describing the electrical discharge machining apparatus 600, we will use the orientation of the manufactured insert 350 as a reference.

[0137] As shown in Figures 28 and 29, the electrical discharge machining apparatus 600 comprises a machining fluid tank 610 in which machining fluid is stored, a support unit 620, a discharge electrode 630, a supply unit 640 for supplying machining fluid, and a recovery unit 650 for recovering machining fluid. The support unit 620 and the discharge electrode 630 are designed to move between a floating position, where they are above the machining fluid in the machining fluid tank 610, and an immersion position, where they are submerged in the machining fluid. Figures 28 and 29 show the support unit 620 and the discharge electrode 630 in the immersion position.

[0138] -Processing liquid tank 610, support part 620- As shown in Figures 28 and 29, the processing fluid tank 610 is a box-shaped structure with an open top, and processing fluid is stored inside the processing fluid tank 610. The support part 620 is a rectangular parallelepiped extending in the depth direction, and a magnet is provided on at least the upper surface 620a of the support part 620. As a result, the metal members 400 and 450 are placed on the upper surface 620a of the support part 620, and the support part 620 supports the metal members 400 and 450 from below. Specifically, the support part 620 is designed to attract and support the metal members 400 and 450 by the magnetic force of the magnet, such that one surface 300a and 350a of the metal members 400 and 450 faces upward and the longitudinal direction of the metal members 400 and 450 faces in the depth direction.

[0139] -Discharge electrode 630- As shown in Figures 28 and 29, the discharge electrode 630 is shaped like a rectangular parallelepiped extending in the depth direction. When the support portion 620 and the discharge electrode 630 are moved to the immersion position, the discharge electrode 630 faces one surface 300a and 350a of the metal members 400 and 450 supported by the support portion 620 in the vertical direction of the device.

[0140] -Supply section 640- The supply unit 640, which supplies the processing fluid, is immersed in the processing fluid and has four supply ports 640a arranged in the depth direction, as shown in Figures 28 and 29. The processing fluid supplied from the supply unit 640 is supplied to the supply region 618 between one surface 300a, 350a of the metal members 400, 450 supported by the support unit 620 and the discharge electrode 630. Specifically, in the depth direction, as shown in Figure 28, the processing fluid supplied from the supply unit 640 is supplied radially from the central part of the area where the vertical holes 302, 352 of the metal members 400, 500 are formed, to the entire supply region 618. The supply region 618 is an example of a region.

[0141] -Recovery Unit 650- As shown in Figures 28 and 29, the recovery unit 650 is positioned on the outside of the metal members 400 and 450 in the depth direction and on one side of the metal members 400 and 450 in the width direction. In the following description, the recovery unit 650 positioned on the outside of the metal members 400 and 450 in the depth direction will be referred to as recovery unit 650a. The recovery unit 650 positioned on one side of the metal members 400 and 450 in the width direction will be referred to as recovery unit 650b. Here, the outside of the metal members 400 and 450 in the depth direction refers to at least one side in the depth direction that is behind the rear end of the metal members 400 and 450, and the side that is in front of the front end of the metal members 400 and 450.

[0142] As shown in Figure 28, the recovery unit 650a is positioned outside the metal members 400 and 450 in the depth direction. Specifically, the recovery unit 650a is positioned on the rear and front sides of the metal members 400 and 450, which are supported by the support unit 620, in the depth direction. The recovery unit 650a is designed to recover the processing fluid that overflows from the recess 612a formed in the upper edge of the side wall 612 of the processing fluid tank 610.

[0143] Furthermore, this recess 612a extends in the width direction at the upper edge of the side wall 612. Specifically, the recess 612a extends in the width direction so as to cover the area in the width direction where the metal members 400 and 450 are arranged. In other words, the recess 612a is formed at the upper edge of the side wall 612 such that, when viewed from above, imaginary lines extending the metal members 400 and 450 in the depth direction intersect at least with the recess 612a.

[0144] Furthermore, as shown in Figure 29, the recovery unit 650b is positioned on one side of the metal members 400 and 450 in the width direction. Specifically, the recovery unit 650 is positioned on the opposite side of the supply unit 640 in the width direction, with the metal members 400 and 450 supported by the support unit 620 in between. The recovery unit 650 is designed to recover the processing fluid that overflows from the recess 614a formed at the upper end of the side wall 614 of the processing fluid tank 610.

[0145] Furthermore, this recess 614a extends in the depth direction along the upper edge of the side wall 614. Specifically, the recess 614a extends in the depth direction so as to cover the area in the depth direction where the metal members 400 and 450 are arranged. In other words, the recess 614a is formed on the upper edge of the side wall 614 such that, when viewed from above, imaginary lines extending the metal members 400 and 450 in the width direction intersect at least with the recess 614a.

[0146] In this configuration, the processing fluid recovered by the recovery unit 650 flows through a recovery path (not shown), passes through a filter that recovers impurities, and is supplied from the supply unit 640. In this way, the processing fluid is circulated.

[0147] [Manufacturing method for nested units 300 and 350] Next, the manufacturing method for the inserts 300 and 350 will be described. The manufacturing method for the inserts 300 and 350 is an example of a manufacturing method for metal parts.

[0148] In the initial state of the electrical discharge machining apparatus 600, the support section 620 and the discharge electrode 630 are moved to a floating position, having emerged from the machining fluid. Then, the metal members 400 and 450 are supported by the support section 620, which has moved to the floating position. Specifically, the metal members 400 and 450 are supported by the support section 620 with their longitudinal direction as the depth direction and one surface 300a and 350a facing upwards.

[0149] Furthermore, the floating support portion 620 and the discharge electrode 630 are moved to the immersion position as shown in Figures 28 and 29. In other words, the support portion 620 and the discharge electrode 630 are immersed in the processing fluid of the processing fluid tank 610 (immersion step). In this state, one surface 300a and 350b of the metal members 400 and 450 face the discharge electrode 630 in the vertical direction of the apparatus.

[0150] Next, the processing fluid is supplied from the supply unit 640. This supplies the processing fluid from the supply unit 640 to the supply area 618 between one surface 300a, 350a of the metal members 400, 450 and the discharge electrode 630. Furthermore, the recovery unit 650 recovers the processing fluid from the processing fluid tank 610. The processing fluid recovered by the recovery unit 650 is supplied from the supply unit 640 through a filter (not shown) (supply and recovery process).

[0151] Here, the supply unit 640 supplies the processing fluid to the supply area 618 from the central portion of the area where the vertical holes 302 and 352 of the metal members 400 and 450 are formed in the depth direction. Furthermore, the recovery unit 650a recovers the processing fluid from the front and back sides of the metal members 400 and 450 in the depth direction. As a result, as shown by the arrows in Figure 30, the processing fluid flows into the vertical holes 302 and 352 from the openings on one side 300a and 350a of the vertical holes 302 and 352. Furthermore, the processing fluid that has flowed into the vertical holes 302 and 352 flows toward the base end of the vertical hole 302 and flows into the horizontal holes 310 and 360. The processing fluid is then discharged from the openings on the front and back sides in the depth direction of the horizontal holes 310 and 360. The processing fluid flows in this manner.

[0152] Next, with the processing fluid flowing, a voltage is applied to the discharge electrode 630, causing a discharge between one surface 300a, 350a of the metal members 400, 450 and the discharge electrode 630 (discharge process). Specifically, the discharge electrode 630 is moved up and down while causing a discharge between one surface 300a, 350a of the metal members 400, 450 and the discharge electrode 630.

[0153] By discharging between surfaces 300a and 350a and the discharge electrode 630, the base ends of the protrusions 402 and 452 formed on the opening edges 302a and 352a shown in Figure 27 melt due to the heat generated by the discharge. As the base ends of the protrusions 402 and 452 melt, they are removed from the opening edges 302a and 352a and become metal fragments. These metal fragments flow with the processing fluid and are discharged to the outside of the metal members 400 and 450. By removing the protrusions 402 and 452 from the metal members 400 and 450, the nesting parts 300 and 350 are manufactured.

[0154] Next, the support portion 620 and the discharge electrode 630 in the immersion position are moved to the floating position, and the nesting components 300 and 350 supported by the support portion 620 are removed.

[0155] -Regarding the metal component 700 related to the comparative form- Next, we will explain the process of machining the metal member 700 related to the comparative form using the electrical discharge machining apparatus 600. First, we will mainly explain the differences between the metal member 700 and the metal member 400.

[0156] As shown in Figure 31, the metal member 700 does not have a transverse hole. In addition, a projection 402 is formed on the opening edge 302a of the vertical hole 302.

[0157] Then, a voltage is applied to the discharge electrode 630, causing a discharge between one surface 300a of the metal member 700 and the discharge electrode 630 (see Figure 28). As a result, the base end of the projection 402 that has formed on the opening edge 302a shown in Figure 31 melts due to the heat generated by the discharge. As the base end of the projection 402 melts, the projection 402 is removed from the opening edge 302a and becomes a metal piece.

[0158] Here, the base end of the vertical hole 302 in the metal member 700 is not connected to a horizontal hole. In other words, the vertical hole 302 in the metal member 700 is bottomed. As a result, the processing fluid accumulates in the vertical hole 302, and some of the metal fragments removed from the opening edge 302a remain in the vertical hole 302 without flowing away. When some of the metal fragments remain in the vertical hole 302, a discharge (secondary discharge) occurs between the remaining metal fragments and the discharge electrode 630, and unintended areas such as the opening edge 302a of the vertical hole 302 are abraded by this secondary discharge.

[0159] (summary) As explained above, in the manufacturing method of the inserts 300 and 350, the metal members 400 and 450 that are subjected to electrical discharge machining in the manufacturing method of the inserts 300 and 350 have horizontal holes 310 and 360 formed therein. Furthermore, the base ends of all vertical holes 302 and 352 are connected to the horizontal holes 310 and 360. In addition, the ends of the horizontal holes 310 and 360 are open to end faces 300b and 350b and end faces 300c and 350c. This allows the machining fluid in the vertical holes 302 and 352 to flow without stagnation.

[0160] Because the processing fluid flows freely within the vertical holes 302 and 352 without stagnation, when removing the protrusions on the opening edges of the vertical holes, where only the tip of the metal member is open, by electrical discharge machining, the amount of metal fragments remaining in the vertical holes 302 and 352 of the metal members 400 and 450 is suppressed compared to when the processing fluid stagnates in the vertical holes. In other words, compared to removing the protrusions 402 on the opening edge 302a of the vertical hole 302 of the metal member 700 in the comparative configuration by electrical discharge machining, the amount of metal fragments remaining in the vertical holes 302 and 352 of the metal members 400 and 450 is suppressed.

[0161] Furthermore, in the manufacturing method of the inserts 300 and 350, both ends of the lateral holes 310 and 360 of the metal members 400 and 450 that are subjected to electrical discharge machining are open. Therefore, compared to the case where only one side of the lateral hole is open, metal fragments are easily discharged from the metal members 400 and 450.

[0162] Furthermore, in the manufacturing method of the nests 300 and 350, the vertical holes 302 and 352 of the metal members 400 and 450 that are subjected to electrical discharge machining are aligned in the depth direction. The base ends of multiple vertical holes 302 and 352 are connected to a single horizontal hole 310 or 360. This reduces the number of horizontal holes compared to the case where a horizontal hole is formed for each of the multiple vertical holes.

[0163] Furthermore, in the discharge step of the manufacturing method for the inserts 300 and 350, the processing fluid supplied from the supply unit 640 is supplied to the supply region 618 between one surface 300a and 350a of the metal members 400 and 450 and the discharge electrode 630. As a result, compared to the case where the processing fluid is supplied towards the discharge electrode, the flow rate of the processing fluid that flows from the tip to the base of the vertical holes 302 and 352 of the metal members 400 and 450 increases.

[0164] Furthermore, in the manufacturing method of the nests 300 and 350, the supply unit 640 supplies the processing fluid to the supply area 618 from the central part of the area in the depth direction where the vertical holes 302 and 352 of the metal members 400 and 450 are formed. In addition, the recovery unit 650a recovers the processing fluid from the front and back sides of the metal members 400 and 450 in the depth direction. As a result, the flow rate of the processing fluid flowing from the front to the base of the vertical holes 302 and 352 of the metal members 400 and 450 increases compared to the case where the area in which the supply unit supplies the processing fluid and the area in which the recovery unit recovers the processing fluid are the same.

[0165] Furthermore, in the manufacturing method of the nesting components 300 and 350, the recovery unit 650a recovers the processing fluid from both the front and back sides of the metal members 400 and 450 in the depth direction. This increases the flow rate of the processing fluid that flows from the front to the base of the vertical holes 302 and 352 of the metal members 400 and 450, compared to the case where the processing fluid is recovered from only one side of the metal member in the depth direction.

[0166] Although this disclosure has described specific embodiments in detail, it will be apparent to those skilled in the art that this disclosure is not limited to these embodiments, and that various other embodiments are possible within the scope of this disclosure. For example, in the above embodiments, both ends of the lateral holes 310 and 360 were open, but only one end of the lateral hole may be open. In this case, the effect achieved by having both ends of the lateral hole open will not be achieved.

[0167] Furthermore, in the above embodiment, the base ends of the multiple vertical holes 302, 352 in the metal members 400, 450 were connected to a single horizontal hole 310, 360, but a horizontal hole may be formed for each vertical hole. In this case, the effect achieved by connecting the base ends of the multiple vertical holes 302, 352 to a single horizontal hole 310, 360 will not be achieved.

[0168] Furthermore, in the above embodiment, the processing fluid was supplied to the supply region 618 between the surface 300a, 350a where the vertical holes 302, 352 are opened and the discharge electrode 630. However, the processing fluid may also be supplied toward the openings of the horizontal holes 310, 360. In this case, the effect achieved by supplying the processing fluid to the supply region 618 will not be achieved.

[0169] Furthermore, in the above embodiment, the recovery unit 650 recovered the processing fluid from above the metal members 400 and 450 in the vertical direction of the device. However, as shown in Figures 32, 33, and 34, the recovery unit 690 may recover the processing fluid from below the metal members 400 and 450. This increases the flow rate of the processing fluid that flows from the tip to the base of the vertical holes 302 and 352 compared to when the processing fluid is recovered from above the metal members.

[0170] (((1))) A process of immersing a metal member, which has one hole extending in one direction with its tip opening on one surface and having a projection on the opening edge, and another hole connected to the base end of the first hole with at least one end opening on the other surface, in a processing fluid such that one surface faces a discharge electrode, A step of discharging a discharge between the surface and the discharge electrode while the processing fluid is flowing, A method for manufacturing metal parts that include [the specified features].

[0171] (((2))) The other holes formed in the metal member immersed in the processing fluid extend in a direction intersecting the one direction and also open to the opposite side of the metal member that faces away from the other side. A method for manufacturing metal parts as described in (((1))).

[0172] (((3))) The metal member immersed in the processing fluid has a plurality of holes arranged in the intersecting direction, and the base ends of the plurality of holes are connected to one of the other holes. A method for manufacturing metal parts as described in (((2))).

[0173] (((4))) In the step of discharging between the surface and the discharge electrode, the processing fluid is supplied to the region between the surface and the discharge electrode. A method for manufacturing metal parts as described in any one of (((1))) to (((3))).

[0174] (((5))) The other holes formed in the metal member immersed in the processing fluid extend in a direction intersecting the one direction, and both ends of the other holes are open in the intersecting direction. The metal member immersed in the processing fluid has a plurality of holes arranged in the intersecting direction, and the base ends of the plurality of holes are connected to one of the other holes. In the step of discharging between the surface and the discharge electrode, the processing fluid is supplied to the region from the central portion of the area in which the first hole is formed in the metal member in the intersecting direction, and the processing fluid is collected from the outside of the metal member in the intersecting direction. The method for manufacturing metal parts as described in (((4))).

[0175] (((6))) In the step of discharging between the aforementioned surface and the discharge electrode, the processing fluid is collected from both outer sides of the metal member in the intersecting direction. A method for manufacturing metal parts as described in (((5))).

[0176] According to the method for manufacturing metal parts of (((1))), when removing the protrusion on the opening edge of a single hole, which is open only at the tip of the metal member, by electrical discharge machining, it is possible to suppress the retention of metal fragments in the single hole compared to when the processing fluid is stagnant in the single hole.

[0177] According to the method for manufacturing metal parts of (((2))), it is possible to suppress the retention of metal fragments in one hole compared to the case where only one of the other holes is open.

[0178] According to the manufacturing method of the metal part described in (((3))), the number of other holes can be reduced compared to the case where multiple holes are formed in each of several holes.

[0179] According to the metal part manufacturing method of (((4))), the flow rate of the processing fluid flowing from the tip to the base of one hole can be increased compared to the case where the processing fluid is supplied toward the discharge electrode.

[0180] According to the metal part manufacturing method of (((5))), the flow rate of the processing fluid flowing from the tip to the base of one hole can be increased compared to the case where the area to which the processing fluid is supplied and the area to which the processing fluid is collected are the same.

[0181] According to the method for manufacturing metal parts of (((6))), the flow rate of the processing fluid that flows from the tip to the base of one hole can be increased compared to the case in which the processing fluid is collected only from the outside of one of the metal members in the intersecting direction. [Explanation of symbols]

[0182] 300 Nesting (an example of a metal product) 300a one side 300b End face (an example of another face) 300c end face (an example of the opposite face) 302 Vertical hole (an example of a single hole) 302a Opening edge 310 Transverse hole (an example of another hole) 350 Nesting (an example of a metal product) 350a one side 350b End face (an example of another face) 350c End face (an example of the opposite face) 352 Vertical hole (an example of a single hole) 352a Opening edge 360 Horizontal hole (an example of another hole) 400 Metal parts 402 Protrusion 450 Metal parts 452 Protrusion 618 Supply Area (Example of an Area) 630 Discharge electrode H. Device in vertical direction (an example of one direction) D. Device depth direction (an example of a crossing direction)

Claims

1. A process of immersing a metal member, which has one hole extending in one direction with its tip opening on one surface and having a projection on the opening edge, and another hole connected to the base end of the first hole with at least one end opening on the other surface, in a processing fluid such that one surface faces a discharge electrode, A step of discharging a discharge between the surface and the discharge electrode while the processing fluid is flowing, A method for manufacturing metal parts that include [the specified features].

2. The other holes formed in the metal member immersed in the processing fluid extend in a direction intersecting the one direction and also open to the opposite side of the metal member that faces away from the other side. A method for manufacturing a metal part according to claim 1.

3. The metal member immersed in the processing fluid has a plurality of holes arranged in the intersecting direction, and the base ends of the plurality of holes are connected to one of the other holes. The method for manufacturing a metal part according to claim 2.

4. In the step of discharging between the surface and the discharge electrode, the processing fluid is supplied to the region between the surface and the discharge electrode. A method for manufacturing a metal part according to claim 1.

5. The other holes formed in the metal member immersed in the processing fluid extend in a direction intersecting the one direction, and both ends of the other holes are open in the intersecting direction. The metal member immersed in the processing fluid has a plurality of holes arranged in the intersecting direction, and the base ends of the plurality of holes are connected to one of the other holes. In the step of discharging between the surface and the discharge electrode, the processing fluid is supplied to the region from the central portion of the area in which the first hole is formed in the metal member in the intersecting direction, and the processing fluid is collected from the outside of the metal member in the intersecting direction. The method for manufacturing a metal part according to claim 4.

6. In the step of discharging between the aforementioned surface and the discharge electrode, the processing fluid is collected from both outer sides of the metal member in the intersecting direction. The method for manufacturing a metal part according to claim 5.

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