Manufacturing method for molded products

Abstract

This invention provides a technology for forming an integral molded product using a first molded product, a second molded product, and a third molded product, in which a molded product having a gate on the leading edge in the ejection direction of the molded product can be used. [Solution] The movable mold 04 is moved so that the first intermediate integral molded product 32 held in the fixed mold 03 and the third molded product 19 held in the movable mold 04 face each other, and the first intermediate integral molded product 32 and the third molded product 19 are joined together with molten resin 20 to form an integral molded product.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a molded product.

Background Art

[0002] In recent years, in order to improve the reliability and strength of joints in molded products and to reduce equipment costs, a method using molten resin for joining molded products has been adopted. Specifically, a plurality of single parts are molded by an injection molding machine. Then, once the mold is opened, the mold is moved so that the single parts face each other. In this state, the mold is closed again, the molded single parts are combined, and molten resin is poured in.

[0003] Patent Document 1 discloses a method for manufacturing an integrally molded product by laminating and joining three molded products, namely, a first molded product, a second molded product, and a third molded product, by injection molding. In the joining of the molded products in Patent Document 1, a method is disclosed in which the joined first molded product and second molded product are joined to the third molded product to obtain an integrally molded product.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Depending on the shape of the molded product, the extraction direction for removing the molded product from the mold after molding may be limited. Furthermore, depending on the shape of the molded product, the gate position may be restricted due to gas venting or void suppression during molding. Also, depending on the shape of the primary molded product, the extraction direction and the injection direction may be the same or opposite, depending on the case. For example, in the case of Patent Document 1, the primary molded product (third molded product) that is joined last has the same ejection and injection directions. However, in some cases, it may be preferable for this primary molded product to have opposite ejection and injection directions. This situation can occur especially if this primary molded product is larger or has a more complex shape than other primary molded products. The method in Patent Document 1 cannot accommodate the case where it is desired to have opposite ejection and injection directions for the third molded product.

[0006] Therefore, the present invention provides a technology for forming an integral molded product using a first molded product, a second molded product, and a third molded product, in which a third molded product with a complex shape that is joined to a joining member formed by joining the first molded product and the second molded product can be used, in which the molding direction and the injection direction are in opposite directions. [Means for solving the problem]

[0007] Therefore, the present invention is a manufacturing method for producing an integral molded product including a first molded product, a second molded product, and a third molded product using a fixed mold and a movable mold, comprising: a first molding step of forming a first intermediate integral molded product by closing the mold with the first molded product held in the fixed mold and the second molded product held in the movable mold facing each other, and joining them by pouring molten resin into the space formed by the first molded product and the second molded product; and a second molding step of closing the mold with the first intermediate integral molded product held in the fixed mold and the third molded product held in the movable mold facing each other, and joining them by pouring molten resin into the space formed by the first intermediate integral molded product and the third molded product. [Effects of the Invention]

[0008] According to the present invention, when forming an integral molded product using a first molded product, a second molded product, and a third molded product, it is possible to provide a technique in which a molded product can be used in which a third molded product with a complex shape that is joined to a joining member formed by joining the first molded product and the second molded product has opposite punching directions and injection directions. [Brief explanation of the drawing]

[0009] [Figure 1] This is a diagram showing a typical injection molding machine. [Figure 2] This is an exploded perspective view of a print head, including a single molded part consisting of three components. [Figure 3] This is a cross-sectional view showing the joint of the first intermediate integrally molded product. [Figure 4] This is a cross-sectional view showing the joint of a single molded product. [Figure 5] This diagram shows how molded parts are joined together using a conventional method. [Figure 6] This figure shows how the molded parts are joined together in this embodiment. [Figure 7] This diagram shows the manufacturing process for a one-piece molded product consisting of three parts, in chronological order. [Figure 8] This is an exploded perspective view of a print head, including a single molded part consisting of four components. [Figure 9] This is a cross-sectional view showing the joint of the first intermediate integrally molded product. [Figure 10] This is a cross-sectional view showing the joint of the second intermediate integrally molded product. [Figure 11] This is a cross-sectional view showing the joint of a single molded product. [Figure 12] This diagram shows the manufacturing process for a one-piece molded product consisting of four parts, in chronological order. [Modes for carrying out the invention]

[0010] (First embodiment) A first embodiment of the present invention will be described below with reference to the drawings.

[0011] FIG. 1 is a diagram showing a conventional general injection molding machine 100. The injection molding machine 100 is provided with a fixed platen 01 that does not move and a movable platen 02 that is movable in the direction of opening and closing the mold, facing each other. The movable platen 02 is movable within the range of the arrow α in the figure. A fixed mold 03 is mounted on the fixed platen 01, and an injection unit 06 for injecting resin is provided. Also, a movable mold 04 is mounted on the movable platen 02. The fixed mold 03 may have a manifold 05 for distributing resin and an injection unit 08 for injecting resin. In the movable mold 04, it is desirable that the manifold 05 for molding the molded product and the manifold 05 for connecting the molded product are independent paths. The injection unit 06 and the manifold 05 are generally provided on the fixed mold 03. The movable platen 02 has an ejector mechanism 07 that is movable in the direction of the arrow β, and the ejector mechanism 07 can remove the molded product of the movable mold 04.

[0012] FIG. 2 is an exploded perspective view of a print head 30 including an integrally molded product 16 composed of three parts in the present embodiment. The integrally molded product 16 included in the print head 30 is formed by joining a first molded product 17, a second molded product 18, and a third molded product 19. The third molded product 19 has a complex shape on its side surface, and when molding, a slide mechanism (slide portion) in which a piece is slidably provided in the cavity of the mold is required.

[0013] FIG. 3 is a cross-sectional view showing the joint portion of a first intermediate integrally molded product 32 in which the first molded product 17 and the second molded product 18 are joined with a molten resin 20. FIG. 4 is a cross-sectional view showing the joint portion of an integrally molded product 33 in which the first intermediate integrally molded product 32 and the third molded product 19 are joined with a molten resin 20.

[0014] The joining of molded products is performed by pouring molten resin 20 into a space portion 31 formed when the molded products are combined. When pouring molten resin 20 into the space portion 31, the vicinity of the space portion 31 through which the molten resin 20 flows is backed up by a backup portion 21 of the mold so as not to yield to the pressure of the molten resin 20. In particular, when the wall is thin, it is effective to perform backup to suppress deformation of the wall. Also, as shown in FIG. 3, by closing the flow path 34 formed in the first molded product 17 by the backup portion 21, the molten resin 20 is prevented from flowing into the flow path 34.

[0015] As the shape of the space portion 31 becomes thinner and longer, the pressure required to pour the molten resin 20 into all of the space portions 31 increases. In that case, the periphery of the contact portion between the molded products may be expanded by the pressure of the molten resin 20, and the molten resin 20 may flow to an unintended portion. Therefore, as shown in FIGS. 3 and 4, by performing backup by the backup portion 21 of the mold at the place where it is expanded, deformation of the molded product and the flow of the molten resin 20 to an unintended portion are suppressed.

[0016] FIG. 5 is a diagram showing the state of joining of each molded product by the method of Patent Document 1 (conventional). In the figure, the Y direction indicates the moving direction of the movable mold 04 with respect to the fixed mold 03, and the arrow 24 indicates the moving direction of the movable mold 04. The Z direction indicates the mold clamping direction of the fixed mold 03 and the movable mold 04. In the method of Patent Document 1, the first intermediate integral molded product obtained by joining the first molded product 17 and the second molded product 18 is left in the movable mold 04, and is opposed to the third molded product 19 having a complicated outer shape of the fixed mold 03, and the first intermediate integral molded product and the third molded product 19 are joined.

[0017] In the primary molding process, injection is performed from the injection unit 06 (see Figure 1) located in the fixed mold 03, forming the first molded product 17, the second molded product 18, and the third molded product 19. A resin inlet called a gate is formed in each molded product. A slide 22 is provided in the part where the complexly shaped third molded product 19 is molded, and the molded third molded product 19 is securely retained in the fixed mold 03 by engaging with the slide 22. Furthermore, when the mold is opened after the primary molding, the first molded product 17 is held in the movable mold 04, and the second molded product 18 is held in the fixed mold 03.

[0018] Subsequently, the movable mold 04 is moved in the Y direction so that the first molded product 17 remaining in the movable mold 04 and the second molded product 18 remaining in the fixed mold 03 face each other. Furthermore, the movable mold 04 and the fixed mold 03 are clamped together, and secondary molding is performed to join the first molded product 17 and the second molded product 18 with molten resin to form the first intermediate integrated molded product.

[0019] During mold opening after secondary molding, the first intermediate integral molded product is held in the movable mold 04. Subsequently, the movable mold 04 is moved in the Y direction so that the first intermediate integral molded product remaining in the movable mold 04 and the third molded product 19 remaining in the fixed mold 03 face each other. Furthermore, the movable mold 04 and the fixed mold 03 are clamped together, and tertiary molding is performed to join the first intermediate integral molded product and the third molded product 19 with molten resin to form an integral molded product.

[0020] The third molded product 19 has a limited direction for removal from the fixed mold 03 after molding (hereinafter referred to as the removal direction), and it is required to be removed in the -Z direction. In the method shown in Figure 5, the third molded product 19 has a gate at its rear end in the removal direction (-Z direction).

[0021] However, depending on the shape of the molded product, it may be preferable to provide a gate at the tip in the venting direction (-Z direction) from the viewpoint of gas venting and void suppression. However, in the example of Figure 5, the third molded product 19 has a limited venting direction, so it is not possible to provide a gate at the tip in the venting direction (-Z direction).

[0022] Therefore, in this embodiment, a manufacturing method is described that allows a gate to be provided at the tip in the extraction direction (-Z direction).

[0023] Figure 6 shows how the molded parts are joined together in this embodiment. In this embodiment, the slide 22 is provided in the movable mold 04 so that the third molded part 19 is held in the movable mold 04 when the mold is opened after the primary molding. When the mold is opened after the secondary molding, the first intermediate integral molded part, which is formed by joining the first molded part 17 and the second molded part 18, is held in the fixed mold 03. Then, the third molded part 19 in the movable mold 04 is brought into contact with the first intermediate integral molded part held in the fixed mold 03, and the first intermediate integral molded part 32 (see Figure 3) and the third molded part 19 are joined together.

[0024] The third molded product 19 has a complex external shape and its punching direction is limited. In molded products with a complex external shape, the position where a gate can be provided may be limited. By making the member on the leading edge in the punching direction the third molded product to be joined last, the gate can be provided on the leading edge in the punching direction.

[0025] In the primary molding process, injection is performed from the injection unit 06 (see Figure 1) located in the fixed mold 03, and the first molded product 17, the second molded product 18, and the third molded product 19 are formed. A resin inlet called a gate (the end of the manifold 05) is formed on each molded product. In the case of Figure 6, the front and back sides of each molded product are reversed compared to the conventional method shown in Figure 5, so the gate is located on the opposite side of each molded product from the molded product formed using the conventional method.

[0026] During mold opening after primary molding, the third molded product 19 remains in the movable mold 04. The first molded product 17 is held in the fixed mold 03, and the second molded product 18 is held in the movable mold 04. Subsequently, the movable mold 04 is moved in the Y direction so that the first molded product 17 remaining in the fixed mold 03 and the second molded product 18 remaining in the movable mold 04 face each other. Furthermore, the movable mold 04 and the fixed mold 03 are clamped together, and secondary molding is performed to join the first molded product 17 and the second molded product 18 with molten resin to form a first intermediate integrated molded product.

[0027] During mold opening after secondary molding, the first intermediate integral molded product is held in the fixed mold 03. Subsequently, the movable mold 04 is moved in the Y direction so that the first intermediate integral molded product remaining in the fixed mold 03 and the third molded product 19 remaining in the movable mold 04 face each other. Furthermore, the movable mold 04 and the fixed mold 03 are clamped together, and tertiary molding is performed to join the first intermediate integral molded product and the third molded product 19 with molten resin to form an integral molded product.

[0028] In this embodiment, a slide 22 is provided in the movable mold 04. However, in a typical injection molding machine, the movable mold 04 has an ejection function, so if the slide 22 is operated by the drive source used for the ejection function, an actuator becomes unnecessary. Specifically, since the ejection function can eject in the opening and closing direction (Z direction), the slide 22 can be operated by placing a cam mechanism, for example, inside the movable mold 04 that is linked to this ejection movement.

[0029] Furthermore, since the movable mold 04 does not have a manifold for supplying molten resin, even if the movable mold 04 is enlarged in the opening and closing direction, it does not affect the overall size of the fixed mold 03 and the movable mold 04 combined. In the movable mold 04, there are fewer constraints on internal space than in the fixed mold 03, so the pitch between adjacent molded products can be reduced compared to when a manifold is provided in the fixed mold 03.

[0030] Figures 7(a) to 7(c) illustrate the manufacturing process of a one-piece molded product 16 consisting of three parts, in chronological order. In the first step shown in Figure 7(a), the first molded product 17, the second molded product 18, and the third molded product 19 are molded. Note that this is just one example, and the first molded product 17, the second molded product 18, and the third molded product 19 may be molded at any point before they are joined together.

[0031] In the state after opening the mold from the first process, the first molded product 17 is held in the fixed mold 03, the second molded product 18 is held in the movable mold 04, and the third molded product 19 is held in the movable mold 04. In this state, the movable mold 04 is moved so that the first molded product 17 and the second molded product 18 face each other, and the mold is closed, resulting in the second process as shown in Figure 7(b). In the second process, molten resin 20 (see Figure 3) is poured into the space 31 (see Figure 3) formed by the combination of the first molded product 17 and the second molded product 18, thereby joining the molded products together and forming the first intermediate integrated molded product 32.

[0032] In the mold-open state from the second step, the first intermediate integral molded product 32 is held in the fixed mold 03, and the third molded product 19 is held in the movable mold 04. In this state, as shown in the upper part of Figure 7(c), the movable mold 04 is moved so that the first intermediate integral molded product 32 held in the fixed mold 03 and the third molded product 19 held in the movable mold 04 face each other, and the mold is closed as shown in the lower part of Figure 7(c). Then, molten resin 20 (see Figure 4) is poured into the space 31 (see Figure 4) formed by combining the first intermediate integral molded product 32 and the third molded product 19 to join the molded products together and mold an integral molded product 33 (third step). After the integral molded product 33 is molded, the engagement between the slide part and the third molded product 19 is released, and the integral molded product 33 is removed from the mold.

[0033] The third molded product 19 may also be molded in the second step. There are advantages and disadvantages to the timing of molding the product. The longer the time between molding and integral molding, the more cooling is possible, making the molded product less likely to deform when the molten resin is poured. Therefore, it is easier to prevent the molten resin from leaking into unintended areas. However, if the time between molding and integral molding is long, the adhesion between the molded product and the molten resin may decrease. Therefore, it is desirable to determine the timing of molding the product based on the combination of materials and molding conditions.

[0034] Furthermore, the means by which the molded parts are moved to opposing positions are not limited. In Figure 6, the movable mold moves laterally to bring them facing each other, but the mold may rotate to bring them facing each other, or the molded parts may be grasped by a robot arm or the like and moved to opposing positions.

[0035] In this way, the movable mold 04 is moved so that the first intermediate integral molded product 32 held in the fixed mold 03 and the third molded product 19 held in the movable mold 04 face each other, and the first intermediate integral molded product 32 and the third molded product 19 are joined by molten resin 20 to form an integral molded product. This provides a technology that allows the use of a molded product with a gate on the leading edge in the removal direction of the molded product when forming an integral molded product using the first molded product, the second molded product and the third molded product.

[0036] (Second embodiment) A second embodiment of the present invention will be described below with reference to the drawings. Since the basic configuration of this embodiment is the same as that of the first embodiment, a characteristic configuration will be described below. In this embodiment, the case of an integrally molded product consisting of four parts will be described.

[0037] Figure 8 is an exploded perspective view of a print head 80 including a single molded product 81 consisting of four parts in this embodiment. The single molded product 81 included in the print head 80 is formed by joining a fourth molded product 25, a fifth molded product 26, a sixth molded product 27, and a seventh molded product 28. The seventh molded product 28 has a complex shape on its side surface, and a sliding mechanism is required in the mold when it is molded.

[0038] Figure 9 is a cross-sectional view showing the joint of the first intermediate integral molded product 82, in which the fourth molded product 25 and the fifth molded product 26 are joined with molten resin 20. Figure 10 is a cross-sectional view showing the joint of the second intermediate integral molded product 83, in which the first intermediate integral molded product 82 and the sixth molded product 27 are joined with molten resin 20. Figure 11 is a cross-sectional view showing the joint of the integral molded product 81, in which the second intermediate integral molded product 83 and the seventh molded product 28 are joined with molten resin 20.

[0039] The joining of molded parts is performed by pouring molten resin 20 into the space 31 formed when the molded parts are joined together. When pouring molten resin 20 into the space 31, the vicinity of the space 31 through which the molten resin 20 flows is backed up by the mold's backup section 21 to prevent it from being overwhelmed by the pressure of the molten resin 20. In particular, when the walls of the molded parts are thin, backing up is effective in suppressing deformation of the walls. Furthermore, as shown in Figure 9, the backup section 21 blocks the flow path 34 formed in the fourth molded part 25, preventing the molten resin 20 from flowing into the flow path 34.

[0040] The narrower and longer the shape of the space 31, the greater the pressure required to flow the molten resin 20 into the entire space 31. In that case, the area around the contact points between the molded parts may be pushed apart by the pressure of the molten resin 20, and the molten resin 20 may flow to unintended areas. Therefore, as shown in Figures 9 and 11, the mold's backup section 21 provides backup in the area that is being pushed apart, thereby suppressing deformation of the molded parts and preventing the molten resin 20 from flowing to unintended areas.

[0041] Figures 12(a) to (d) illustrate the manufacturing process of an integrally molded product 81 consisting of four parts, in chronological order. In the first step shown in Figure 12(a), the fourth molded product 25, the fifth molded product 26, the sixth molded product 27, and the seventh molded product 28 are molded. Note that this is just one example, and the fourth molded product 25, the fifth molded product 26, the sixth molded product 27, and the seventh molded product 28 may be molded at any point before joining them together.

[0042] In the state after opening the mold from the first process, the fourth molded product 25 is held in the fixed mold 03, the fifth molded product 26 is held in the movable mold 04, the sixth molded product 27 is held in the fixed mold 03, and the seventh molded product 28 is held in the movable mold 04. In this state, the movable mold 04 is moved so that the fourth molded product 25 and the fifth molded product 26 face each other, and the mold is closed, resulting in the second process as shown in Figure 12(b). In the second process, the molded products are joined together by pouring molten resin 20 (see Figure 9) into the space 31 (see Figure 9) formed by combining the fourth molded product 25 and the fifth molded product 26, thereby forming the first intermediate integral molded product 82.

[0043] In the mold-open state from the second step, the first intermediate integral molded product 82 is held in the movable mold 04, and the sixth molded product 27 is held in the fixed mold 03. In this state, as shown in the upper part of Figure 12(c), the movable mold 04 is moved so that the first intermediate integral molded product 82 held in the movable mold 04 and the sixth molded product 27 held in the fixed mold 03 face each other, and the mold is closed as shown in the lower part of Figure 12(c). Then, molten resin 20 (see Figure 10) is poured into the space 31 (see Figure 10) formed by combining the first intermediate integral molded product 82 and the sixth molded product 27 to join the molded products together and mold the second intermediate integral molded product 83 (third step).

[0044] In the mold-open state from the third step, the second intermediate integral molded product 83 is held in the fixed mold 03, and the seventh molded product 28 is held in the movable mold 04. In this state, as shown in the upper part of Figure 12(d), the movable mold 04 is moved so that the seventh molded product 28 held in the movable mold 04 and the second intermediate integral molded product 83 held in the fixed mold 03 face each other, and the mold is closed as shown in the lower part of Figure 12(d). Then, molten resin 20 (see Figure 11) is poured into the space 31 (see Figure 11) formed by combining the second intermediate integral molded product 83 and the seventh molded product 28 to join the molded products together and form an integral molded product 81 (fourth step).

[0045] Thus, the present invention can also be applied to the molding of an integrally molded product consisting of four parts. Of the four parts, the seventh molded product 28, which has the most complex shape, is formed in the first step by the resin flow supplied from the manifold 05 of the fixed mold 03, and is held in the movable mold 04 by the slide 22 until the second intermediate integrally molded product 83 is joined in the fourth step. After the integrally molded product is formed, the entire integrally molded product can be removed from the mold by the slide 22 provided in the movable mold 04.

[0046] Furthermore, the present invention may also be applied to the molding of an integrally molded product consisting of five or more parts. In any case, the molded product having the most complex shape among the multiple parts formed in the first step should be held in the movable mold. Then, in the final molding step in which the integrally molded product is completed, this part should be joined with other intermediate integrally molded products, and the entire integrally molded product should be removed from the mold by a slide 22 provided in the movable mold.

[0047] This embodiment includes the following methods.

[0048] (Method 1) A manufacturing method for producing an integrally molded product including a first molded product, a second molded product, and a third molded product using a fixed mold and a movable mold, A first molding step involves closing the molds with the first molded product held in the fixed mold and the second molded product held in the movable mold facing each other, and then joining them by pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. A method for manufacturing a molded product, comprising: a second molding step of closing the mold with the first intermediate integral molded product held in the fixed mold and the third molded product held in the movable mold facing each other, and joining them by pouring molten resin into the space formed by the first intermediate integral molded product and the third molded product.

[0049] (Method 2) A method for manufacturing a molded product according to Method 1, comprising a molding step of closing the fixed mold and the movable mold to form the first molded product, the second molded product, and the third molded product.

[0050] (Method 3) The method for manufacturing a molded product according to method 2, wherein in the first molding step and the second molding step, molten resin is injected from an injection unit provided in the fixed mold.

[0051] (Method 4) The method for manufacturing a molded product according to Method 3, wherein the injection unit provided in the fixed mold is a first injection unit and a second injection unit, and in the molding process of the molded product, molten resin is injected from the first injection unit, and in the first molding process and the second molding process, molten resin is injected from the second injection unit.

[0052] (Method 5) A method for manufacturing a molded product according to any one of methods 1 to 4 for sliding the movable mold in order to bring the first molded product and the second molded product facing each other.

[0053] (Method 6) The method for manufacturing a molded product according to Method 1, wherein the movement of the movable mold is rotational movement in a plane opposite to the fixed mold.

[0054] (Method 7) A method for manufacturing a molded product according to any one of methods 1 to 4, which involves using a robotic arm to bring the first molded product and the second molded product facing each other.

[0055] (Method 8) A method for manufacturing a molded article according to method 3 or 4, wherein the molten resin injected from the injection unit is distributed by a manifold provided in the fixed mold.

[0056] (Method 9) A method for manufacturing a molded product according to any one of methods 1 to 8, wherein, after the second molding step, a slidable sliding portion of the movable mold is slid to release the engagement between the sliding portion and the third molded product.

[0057] (Method 10) The method for manufacturing a molded product according to method 9, wherein the third molded product formed by the first molding step is held in the movable mold when the fixed mold and the movable mold are opened by engaging with the slide portion.

[0058] (Method 11) A method for manufacturing a molded article according to any one of methods 1 to 10, wherein in the first molding step and the second molding step, a mold is used for backup to suppress deformation of the molded article.

[0059] (Method 12) A manufacturing method for producing an integrally molded product including a first molded product, a second molded product, a third molded product, and a fourth molded product using a fixed mold and a movable mold, A first molding step involves closing the molds with the first molded product held in the fixed mold and the second molded product held in the movable mold facing each other, and then joining them by pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. A second molding step involves closing the molds with the first intermediate integral molded product held in the movable mold and the third molded product held in the fixed mold facing each other, and joining them by pouring molten resin into the space formed by the first intermediate integral molded product and the third molded product to form a second intermediate integral molded product. A method for manufacturing a molded product, comprising: a third molding step of closing the mold with the second intermediate integral molded product held in the fixed mold and the fourth molded product held in the movable mold facing each other, and joining them by pouring molten resin into the space formed by the second intermediate integral molded product and the fourth molded product.

[0060] (Method 13) A method for manufacturing a molded product, comprising forming an integral molded product using a first molded product, a second molded product, and a third molded product with a fixed fixed mold and a movable mold, A first molding step involves closing a mold with the first molded product and the second molded product facing each other, and joining them by pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. The process includes a second molding step in which the first intermediate integral molded product held in the fixed mold and the third molded product held in the movable mold are placed facing each other and the mold is closed, and molten resin is poured into the space formed by the first intermediate integral molded product and the third molded product to join them, A method for manufacturing a molded product, characterized in that, in the first molding step and the second molding step, molten resin is injected from an injection unit provided in the fixed mold.

[0061] (Method 14) A manufacturing method for producing an integrally molded product including a first molded product, a second molded product, and a third molded product, using a fixed mold and a movable mold that is movable relative to the fixed mold, A first molding step involves forming the first molded product, the second molded product, and the third molded product by introducing resin through a manifold provided in the fixed mold while the fixed mold and the movable mold are closed, With the sliding portion provided in the movable mold in contact with the third molded product, the fixed mold and the movable mold are opened, the first molded product is held in the fixed mold, and the second molded product and the third molded product are held in the movable mold. A second molding step involves closing the fixed mold and the movable mold with the first molded product held in the fixed mold and the second molded product held in the movable mold facing each other, and then pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. A third molding step involves forming the integral molded product by closing the molds with the first intermediate integral molded product held in the fixed mold and the third molded product held in the movable mold facing each other, and then joining them by pouring molten resin into the space formed by the first intermediate integral molded product and the third molded product, The process involves opening the fixed mold and the movable mold, and removing the integrally molded product by sliding the sliding part. A method for manufacturing a molded article, characterized by having the following features. [Explanation of Symbols]

[0062] 03 Fixed mold 04 Movable mold 17 First molded product 18 Second molded product 19 Third molded product 20 Molten resin 32 First intermediate integrally molded product

Claims

1. A manufacturing method for producing an integrally molded product including a first molded product, a second molded product, and a third molded product using a fixed mold and a movable mold, A first molding step involves closing the molds with the first molded product held in the fixed mold and the second molded product held in the movable mold facing each other, and then joining them by pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. A method for manufacturing a molded product, comprising: a second molding step of closing the mold with the first intermediate integral molded product held in the fixed mold and the third molded product held in the movable mold facing each other, and joining them by pouring molten resin into the space formed by the first intermediate integral molded product and the third molded product.

2. A method for manufacturing a molded product according to claim 1, comprising a molding step of closing the fixed mold and the movable mold to form the first molded product, the second molded product, and the third molded product.

3. The method for manufacturing a molded article according to claim 2, wherein in the first molding step and the second molding step, molten resin is injected from an injection unit provided in the fixed mold.

4. The method for manufacturing a molded product according to claim 3, wherein the injection unit provided in the fixed mold is a first injection unit and a second injection unit, and in the molding process of the molded product, molten resin is injected from the first injection unit, and in the first molding process and the second molding process, molten resin is injected from the second injection unit.

5. A method for manufacturing a molded product according to claim 1, wherein the movable mold is slid to face the first molded product and the second molded product.

6. The method for manufacturing a molded article according to claim 1, wherein the movement of the movable mold is rotational movement in a plane facing the fixed mold.

7. A method for manufacturing a molded product according to claim 1, wherein a robotic arm is used to bring the first molded product and the second molded product facing each other.

8. The method for manufacturing a molded article according to claim 3, wherein the molten resin injected from the injection unit is distributed by a manifold provided in the fixed mold.

9. The method for manufacturing a molded product according to claim 1, wherein, after the second molding step, the slidable sliding portion of the movable mold is slid to release the engagement between the sliding portion and the third molded product.

10. The method for manufacturing a molded product according to claim 9, wherein the third molded product formed by the first molding step is held in the movable mold when the fixed mold and the movable mold are opened by engaging with the slide portion.

11. The method for manufacturing a molded article according to claim 1, wherein in the first molding step and the second molding step, a mold is used for backup in order to suppress deformation of the molded article.

12. A manufacturing method for producing an integrally molded product including a first molded product, a second molded product, a third molded product, and a fourth molded product, using a fixed mold and a movable mold, A first molding step involves closing the molds with the first molded product held in the fixed mold and the second molded product held in the movable mold facing each other, and then joining them by pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. A second molding step involves closing the molds with the first intermediate integral molded product held in the movable mold and the third molded product held in the fixed mold facing each other, and joining them by pouring molten resin into the space formed by the first intermediate integral molded product and the third molded product to form a second intermediate integral molded product. A method for manufacturing a molded product, comprising: a third molding step of closing the mold with the second intermediate integral molded product held in the fixed mold and the fourth molded product held in the movable mold facing each other, and joining them by pouring molten resin into the space formed by the second intermediate integral molded product and the fourth molded product.

13. A method for manufacturing a molded product, comprising forming an integral molded product using a first molded product, a second molded product, and a third molded product with a fixed fixed mold and a movable mold, A first molding step involves closing a mold with the first molded product and the second molded product facing each other, and joining them by pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. The process includes a second molding step in which the first intermediate integral molded product held in the fixed mold and the third molded product held in the movable mold are placed facing each other and the mold is closed, and molten resin is poured into the space formed by the first intermediate integral molded product and the third molded product to join them, A method for manufacturing a molded product, characterized in that, in the first molding step and the second molding step, molten resin is injected from an injection unit provided in the fixed mold.

14. A manufacturing method for producing an integrally molded product including a first molded product, a second molded product, and a third molded product using a fixed mold and a movable mold that is movable relative to the fixed mold, A first molding step involves forming the first molded product, the second molded product, and the third molded product by introducing resin through a manifold provided in the fixed mold while the fixed mold and the movable mold are closed, With the sliding portion provided in the movable mold in contact with the third molded product, the fixed mold and the movable mold are opened, the first molded product is held in the fixed mold, and the second molded product and the third molded product are held in the movable mold. A second molding step involves closing the fixed mold and the movable mold with the first molded product held in the fixed mold and the second molded product held in the movable mold facing each other, and then pouring molten resin into the space formed by the first molded product and the second molded product to form a first intermediate integral molded product. A third molding step involves forming the integral molded product by closing the molds with the first intermediate integral molded product held in the fixed mold and the third molded product held in the movable mold facing each other, and then joining them by pouring molten resin into the space formed by the first intermediate integral molded product and the third molded product, The process involves opening the fixed mold and the movable mold, and removing the integrally molded product by sliding the sliding part. A method for manufacturing a molded article, characterized by having the following features.

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