Molding system

Abstract

To provide a simple molding system that can stabilize the quality of molded products. [Solution] The molding system includes a clamping device 10 that clamps a fixed mold 3 and a movable mold 4 that hold an insert part 100 in its thickness direction, an injection device having a plunger 21 that pushes adhesive 300 into the insert part 100, and a control device that controls the clamping device 10 and the injection device. When the toggle link mechanism 17 of the clamping device 10 is bent, the control device adjusts the distance between the movable die plate 12 and the tailstock 13 of the clamping device 10 to a size corresponding to the thickness of the insert part 100. Then, the control device extends the toggle link mechanism 17 to clamp the fixed mold 3 and the movable mold 4.

Description

Technical Field

[0001] The present invention relates to a molding system that sandwiches an insert part between a fixed mold and a movable mold and integrally molds a resin with the insert part.

Background Art

[0002] Patent Document 1 discloses a conventional transfer molding machine. The transfer molding machine disclosed in Patent Document 1 is used to mold a product in which an insert part (work), which is a substrate on which a semiconductor chip is mounted, and a resin covering the semiconductor chip are integrated. The transfer molding machine has an upper mold, a lower mold, and a toggle link mechanism used for clamping the upper mold and the lower mold. The upper mold and the lower mold are provided with movable parts supported by springs, and the insert part is sandwiched between the respective movable parts. When the upper mold and the lower mold are clamped, the springs contract according to the thickness of the insert part. Thereby, it is suppressed that the quality of the molded product becomes non-uniform due to variations in the thickness of the insert part.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the above-described transfer molding machine, since the structures of the upper mold and the lower mold are complicated, there is a risk that the manufacturing cost increases.

[0005] Therefore, an object of the present invention is to provide a molding system having a simple structure that can stabilize the quality of a molded product.

Means for Solving the Problems

[0006] To achieve the above objective, a molding system according to one aspect of the present invention is a molding system comprising: a clamping device for clamping a fixed mold and a movable mold; a plunger for pushing resin into a space formed in an insert part sandwiched in the thickness direction between the fixed mold and the movable mold; and a control device for controlling the clamping device, wherein the clamping device comprises: a fixed die plate to which the fixed mold is attached; a movable die plate to which the movable mold is attached and facing the fixed die plate in the clamping direction; a tailstock that faces the movable die plate in the clamping direction with the fixed die plate in between; a plurality of tie bars connecting the movable die plate and the tailstock; and a toggle link mechanism disposed between the fixed die plate and the tailstock that bends and extends, wherein when the toggle link mechanism is bent, the control device adjusts the distance between the movable die plate and the tailstock to a size corresponding to the thickness of the insert part, extends the toggle link mechanism, and clamps the fixed mold and the movable mold.

[0007] To achieve the above objective, another aspect of the present invention provides a molding system comprising: a clamping device for clamping a fixed mold and a movable mold; a plunger for pushing resin into a space formed in an insert component sandwiched in the thickness direction between the fixed mold and the movable mold; and a control device for controlling the clamping device, wherein the clamping device comprises: a fixed die plate to which the fixed mold is attached; a movable die plate to which the movable mold is attached and facing the fixed die plate in the clamping direction; a tailstock that faces the fixed die plate in the clamping direction with the movable die plate in between; a plurality of tie bars connecting the fixed die plate and the tailstock; and a toggle link mechanism disposed between the movable die plate and the tailstock that bends and extends, wherein the control device, when the toggle link mechanism is bent, adjusts the distance between the fixed die plate and the tailstock to a size corresponding to the thickness of the insert component, extends the toggle link mechanism, and clamps the fixed mold and the movable mold. [Effects of the Invention]

[0008] When the toggle link mechanism is bent, the control device adjusts the distance between the tailstock and the die plate connected to it by a tie bar to a size corresponding to the thickness of the insert component, and then extends the toggle link mechanism to clamp the fixed mold and the movable mold together. In this way, an appropriate clamping force can be applied to the fixed mold and the movable mold that hold the insert component. This suppresses inconsistent quality of molded products caused by variations in the thickness of the insert component. Therefore, the quality of molded products can be stabilized in a molding system with a relatively simple structure. [Brief explanation of the drawing]

[0009] [Figure 1] A side view of a molding system according to one embodiment of the present invention. [Figure 2] Figure 1 is a plan view of the molding system. [Figure 3]Figure 1 is a functional block diagram of the molding system. [Figure 4] This figure shows the products manufactured using the molding system shown in Figure 1. [Figure 5] Figure 4 is a perspective view showing the insert components and multiple magnets of the product. [Figure 6] This is a cross-sectional view (part 1) illustrating an example of the operation of the molding system shown in Figure 1. [Figure 7] This is a cross-sectional view (part 2) illustrating an example of the operation of the molding system shown in Figure 1. [Figure 8] This is a cross-sectional view illustrating an example of the operation of the molding system shown in Figure 1 (part 3). [Figure 9] This is a cross-sectional view illustrating an example of the operation of the molding system shown in Figure 1 (part 4). [Figure 10] This is a cross-sectional view illustrating an example of the operation of the molding system shown in Figure 1 (part 5). [Figure 11] This is a cross-sectional view illustrating an example of the operation of the molding system shown in Figure 1 (part 6). [Figure 12] This is a cross-sectional view illustrating an example of the operation of the molding system shown in Figure 1 (part 7). [Modes for carrying out the invention]

[0010] The configuration of a molding system according to one embodiment of the present invention will be described below with reference to Figures 1 to 12.

[0011] Figures 1 and 2 are side and top views, respectively, of a molding system according to one embodiment of the present invention. Figure 3 is a functional block diagram of the molding system of Figure 1. Figure 4A is a top view of a product manufactured by the molding system of Figure 1, and Figure 4B is a cross-sectional view taken along line BB of Figure 4A. Figure 5 is a perspective view showing the insert parts and multiple magnets of the product of Figure 4. Figures 6 to 12 are cross-sectional views illustrating an example of the operation of the molding system of Figure 1.

[0012] The molding system of this embodiment includes a vertical molding machine that opens and closes a fixed mold and a movable mold in the vertical direction. The present invention is also applicable to a horizontal molding machine that opens and closes a fixed mold and a movable mold in the horizontal direction.

[0013] The molding system 1 according to this embodiment is used to produce a product 200, which is a molded product, by filling resin into the space formed in the insert part 100.

[0014] First, the product 200 will be described with reference to FIGS. 4 and 5.

[0015] The product 200 is, for example, a rotor used in an electric motor of an electric vehicle. As shown in FIGS. 4 and 5, the product 200 has an insert part 100, a plurality of magnets 110, and a plurality of resin parts 120.

[0016] The insert part 100 has a cylindrical shape. The insert part 100 has a plurality of magnet holes 105 extending from one end face 100a to the other end face 100b. The shape of the magnet hole 105 when viewed from the central axis L direction is trapezoidal. The plurality of magnet holes 105 are arranged side by side in the circumferential direction. The central axis L direction is the thickness direction of the insert part 100.

[0017] The insert part 100 is formed by laminating a plurality of electromagnetic steel sheets 101 having an annular shape in the central axis L direction. Therefore, the tolerances of the thicknesses of the electromagnetic steel sheets 101 are stacked, and the length of the insert part 100 in the central axis L direction (the thickness of the insert part 100) may vary. On the other hand, the outer diameter and the inner diameter of the insert part 100 have relatively little variation. Note that the insert part 100 is not limited to being formed by laminating a plurality of plates. The insert part 100 may be, for example, obtained by machining a cylindrical metal workpiece.

[0018] Multiple magnets 110 have a rod shape. When viewed from the direction of the central axis L, the shape of the magnet 110 is trapezoidal. The radial length of the magnet 110 (height of the trapezoid) is shorter than the radial length of the magnet hole 105. Multiple magnets 110 are inserted into multiple magnet holes 105. The magnets 110 are positioned towards the radially outer side of the magnet hole 105.

[0019] Multiple resin parts 120 are formed into rod shapes by solidifying an adhesive 300 containing a thermosetting resin that is filled into the radially inward portion (space 107) of the magnet hole 105. The shape of the resin part 120 when viewed from the direction of the central axis L is trapezoidal. The resin part 120 fills the gap between the inner circumferential surface of the magnet hole 105 and the magnet 110, thereby joining the insert part 100 and the magnet 110. Note that the resin part 120 may contain a thermoplastic resin instead of a thermosetting resin.

[0020] Next, the molding system 1 will be described with reference to Figures 1 to 3 and Figure 9.

[0021] As shown in Figures 1 to 3, the molding system 1 includes an automatic machine 5, a measuring device 6, and a transfer molding machine 7.

[0022] The automated machine 5 has a transport arm and is used to move the insert part 100, multiple magnets 110, product 200, and adhesive 300. The automated machine 5 is located near the measuring device 6 and the transfer molding machine 7.

[0023] The measuring device 6 measures the thickness of the insert part 100 in the direction of its central axis L. The measuring device 6 has a press mechanism that compresses the insert part 100 in the direction of its central axis L. The measuring device 6 is located near the downstream end of a conveyor (not shown) that transports the insert part 100. The insert part 100 is heated during transport by the conveyor to a temperature suitable for filling with adhesive 300. The measuring device 6 compresses the insert part 100, which has been moved from the conveyor by the automatic machine 5 and placed on the measuring device 6, in the direction of its central axis L using the press mechanism, and then measures the thickness of the insert part 100. This allows for more accurate measurement of the thickness of the insert part 100.

[0024] The transfer molding machine 7 includes a mold clamping device 10, an injection device 20, and a control device 30.

[0025] The die clamping device 10 includes a rotary table 11, a movable die plate 12, a tailstock 13, a plurality of tie bars 14, a rotary drive mechanism 15, an adjustment device 16, and a toggle link mechanism 17.

[0026] The rotary table 11 has a disc shape and is rotatably mounted on a base 9 supported by a frame 8. Two fixed-side molds 3 are mounted on the rotary table 11 at 180-degree intervals. The rotary table 11 is rotated by a rotary drive mechanism 15, alternately positioning the two fixed-side molds 3 at the first station S1 (left position in Figures 1 and 2) and the second station S2 (right position in Figures 1 and 2). The base 9 and the rotary table 11 are fixed die plates.

[0027] The movable die plate 12 is positioned above the rotary table 11. The movable die plate 12 is movable in the vertical direction. The vertical direction is the clamping direction. The movable die plate 12 is provided with a pot 12a, which is a circular hole. A cylindrical solid adhesive 300 is fed into the pot 12a by an automatic machine 5.

[0028] The movable die plate 12 is fitted with the movable mold 4. The movable mold 4 has an upper mold 4a and a lower mold 4b that are separable in the vertical direction. The movable mold 4 is provided with a runner and a gate that lead to the pot 12a. The movable mold 4 faces the fixed mold 3 located at the second station S2 in the vertical direction.

[0029] The tailstock 13 is positioned below the base 9 so as to be movable in the vertical direction. Multiple tie bars 14 extend vertically through the base 9 and connect the movable die plate 12 and the tailstock 13. The vertical distance between the movable die plate 12 and the tailstock 13 can be adjusted by an adjustment device 16.

[0030] The toggle link mechanism 17 is located between the base 9 and the tailstock 13. The toggle link mechanism 17 bends as shown in Figures 9 and 12, and extends as shown in Figures 10 and 11.

[0031] When the toggle link mechanism 17 bends, the distance between the base 9 and the tailstock 13 decreases, and the distance between the rotary table 11 and the movable die plate 12, which are positioned on the base 9, increases, causing the movable mold 4 to move away from the fixed mold 3. The fixed mold 3 and the movable mold 4 become separated. At this time, the upper mold 4a and the lower mold 4b of the movable mold 4 separate in the vertical direction.

[0032] As the toggle link mechanism 17 extends, the distance between the base 9 and the tailstock 13 increases, and the distance between the rotary table 11 and the movable die plate 12, which are positioned on the base 9, decreases, bringing the movable mold 4 closer to the fixed mold 3. The fixed mold 3 and the movable mold 4 then clamp the insert part 100. At this time, the upper mold 4a and the lower mold 4b of the movable mold 4 come into contact, and the runner of the movable mold 4 communicates with the pot 12a.

[0033] The injection device 20 is positioned above the movable die plate 12. The injection device 20 has a cylindrical plunger 21. The plunger 21 is movable in the vertical direction, and the tip of the plunger 21 is inserted into the pot 12a.

[0034] The control device 30 controls the operation of the entire molding system 1. The control device 30 has a microcomputer. The control device 30 controls the automatic machine 5, the measuring device 6, the clamping device 10 (rotary drive mechanism 15, adjustment device 16, toggle link mechanism 17), and the injection device 20.

[0035] An example of the operation for producing product 200 in the molding system 1 (control device 30) will be explained with reference to Figures 6 to 12.

[0036] (1) The control device 30 controls the automatic machine 5 to move the insert part 100 from the conveyor and place it on the measuring device 6.

[0037] (2) The control device 30 controls the measuring device 6 to compress the insert part 100 in the direction of the central axis L, and then measures the thickness of the insert part 100.

[0038] (3) The control device 30 controls the automatic machine 5 to move the insert part 100 whose thickness has been measured from the measuring device 6 and place it on the fixed mold 3 positioned at the first station S1 (Figure 6). The insert part 100 is placed on the fixed mold 3 so that its central axis L is aligned in the vertical direction.

[0039] (4) The control device 30 controls the automatic machine 5 to insert multiple magnets 110 into multiple magnet holes 105 of the insert part 100 (Figure 7).

[0040] (5) When the control device 30 confirms that the toggle link mechanism 17 is bent (i.e., that the fixed mold 3 and the movable mold 4 located at the second station S2 are in an open state), it controls the rotary drive mechanism 15 to rotate the rotary table 11 by 180 degrees. As a result, the fixed mold 3 on which the insert part 100 is placed moves from the first station S1 to the second station S2, and the fixed mold 3 on which the product 200 is placed moves from the second station S2 to the first station S1.

[0041] (6) When the product 200 is placed on the fixed mold 3 located at the first station S1, the control device 30 controls the automatic machine 5 to move the product 200 from the fixed mold 3 and place it in a predetermined product storage area (Figure 8).

[0042] (7) When the toggle link mechanism 17 is bent, the control device 30 controls the adjustment device 16 to adjust the distance between the movable die plate 12 and the tailstock 13 to a size corresponding to the thickness of the insert part 100 located at the second station S2 (Figure 9).

[0043] The operation described in (7) above will now be explained in detail. The memory unit of the control device 30 stores a table that associates the thickness (thickness T) of the insert part 100 with the size (size M) of the gap between the movable die plate 12 and the tailstock 13. When the thickness of the insert part 100 sandwiched between the fixed mold 3 and the movable mold 4 is thickness T and the size of the gap between the movable die plate 12 and the tailstock 13 is size M corresponding to thickness T, an appropriate clamping force can be applied to the insert part 100. The control device 30 obtains the thickness T measured for the insert part 100 at the second station S2, obtains the size M corresponding to thickness T from the table, and controls the adjustment device 16 so that the gap between the movable die plate 12 and the tailstock 13 becomes size M.

[0044] The control device 30 may store the thickness of a reference insert part 100 (thickness T0), the size of the gap between the movable die plate 12 and the tailstock 13 set for the reference insert part 100 (size M0), and the amount of change in the size of the gap per unit thickness (change amount Mu). The control device 30 obtains the thickness T measured for the insert part 100 at the second station S2, obtains a value (value Mx) obtained by subtracting thickness T0 from thickness T and multiplying the change amount Mu, and controls the adjustment device 16 so that the gap between the movable die plate 12 and the tailstock 13 is the sum of size M0 and value Mx. For example, if the thickness T0 is 300 mm, the size M0 is 1200 mm, the change in size Mu per 1 mm of thickness is 1 mm, and the thickness T measured for the insert part 100 is 298 mm, then the size of the gap between the movable die plate 12 and the tailstock 13 that provides an appropriate clamping force is M0 + Mx = M0 + (T - T0) × Mu = 1200 + (298 - 300) × 1 = 1198 mm.

[0045] Furthermore, the thickness of the insert component 100 may be divided into multiple stages, and the memory unit of the control device 30 may store the size (size Ms) of the gap between the movable die plate 12 and the tailstock 13, which is set to correspond to the multiple stages. The sizes Ms set to correspond to the multiple stages are all different. For example, a thickness of less than 298 mm may be called the "thin stage," a thickness of 298 mm or more and 302 mm or less may be called the "standard stage," and a thickness of more than 302 mm may be called the "thick stage." The size Ms corresponding to the "thin stage" may be set to 1198 mm, the size Ms corresponding to the "standard stage" may be set to 1200 mm, and the size Ms corresponding to the "thick stage" may be set to 1202 mm. In this configuration, the control device 30 acquires the stage that includes the thickness T measured for the insert component 100 at the second station S2, acquires the size Ms corresponding to that stage from the table, and controls the adjustment device 16 so that the gap between the movable die plate 12 and the tailstock 13 is size Ms.

[0046] (8) The control device 30 controls the toggle link mechanism 17 to extend it and clamp the fixed mold 3 and the movable mold 4 located at the second station S2 (Figure 10). As a result, the upper mold 4a and the lower mold 4b of the movable mold 4 come into contact, the insert part 100 is sandwiched between the fixed mold 3 and the movable mold 4, and the pot 12a communicates with the space 107 of the insert part 100 (a location closer to the radially inward side of the magnet hole 105) via the runner and gate of the movable mold 4. At this time, the distance between the movable die plate 12 and the tailstock 13 is adjusted to a size corresponding to the thickness of the insert part 100 at the second station S2, so that an appropriate clamping force is applied to the insert part 100.

[0047] (9) The control device 30 controls the automatic machine 5 to pour the adhesive 300 into the pot 12a (Figure 10). At this time, the fixed mold 3 and the movable mold 4 are heated to a temperature suitable for filling with adhesive 300. The adhesive 300 poured into the pot 12a begins to melt.

[0048] (10) The control device 30 controls the injection device 20 to move the plunger 21 downward (Figure 11). This allows the adhesive 300 to pass through the runner and gate of the movable mold 4 and fill the space 107 of the insert part 100.

[0049] (11) After the adhesive 300 filling the space 107 has solidified and become the resin part 120, the control device 30 controls the toggle link mechanism 17 to bend the toggle link mechanism 17 and open the fixed mold 3 and the movable mold 4 which are positioned at the second station S2 (Figure 12). As a result, the upper mold 4a and the lower mold 4b of the movable mold 4 open, the runner resin 310 between them is removed, and the movable mold 4 separates from the product 200.

[0050] Thereafter, the control device 30 repeats the operations (1) to (11) described above.

[0051] As described above, the molding system 1 includes a clamping device 10 for clamping a fixed mold 3 and a movable mold 4, an injection device 20 having a plunger 21 for pushing adhesive 300 into a space 107 formed in an insert part 100 sandwiched in the thickness direction between the fixed mold 3 and the movable mold 4, and a control device 30 for controlling the clamping device 10 and the injection device 20. The clamping device 10 includes a rotary table 11 to which the fixed mold 3 is attached, a movable die plate 12 to which the movable mold 4 is attached and which faces the rotary table 11 in the vertical direction, a tail stock 13 that faces the movable die plate 12 in the vertical direction with the rotary table 11 in between, a plurality of tie bars 14 connecting the movable die plate 12 and the tail stock 13, and a toggle link mechanism 17 that is positioned between the rotary table 11 and the tail stock 13 and which bends and extends. When the toggle link mechanism 17 is bent, the control device 30 adjusts the distance between the movable die plate 12 and the tailstock 13 to a size corresponding to the thickness of the insert part 100, extends the toggle link mechanism 17, and clamps the fixed mold 3 and the movable mold 4.

[0052] In this way, the molding system 1 can apply appropriate clamping force to the fixed mold 3 and the movable mold 4 that hold the insert part 100. This suppresses the non-uniformity of the product 200 quality caused by variations in the thickness of the insert part 100. Therefore, the quality of the product 200 can be stabilized in a molding system 1 with a relatively simple structure.

[0053] The molding system 1 described above has a movable die plate 12 and a tailstock 13 connected by a plurality of tie bars 14, and a control device 30 adjusts the distance between the movable die plate 12 and the tailstock 13 to a size corresponding to the thickness of the insert part 100. However, the present invention is not limited to this configuration. For example, the present invention may be applied to a molding system in which the tailstock faces the fixed die plate with the movable die plate in between, the fixed die plate and the tailstock are connected by a plurality of tie bars, a toggle link mechanism is positioned between the movable die plate and the tailstock, and a control device adjusts the distance between the fixed die plate and the tailstock to a size corresponding to the thickness of the insert part.

[0054] Furthermore, although the molding system 1 has the fixed mold 3 placed on the rotary table 11, instead of the rotary table 11, for example, a slide table that slides in the left-right direction in Figure 1 may be provided, and the fixed mold 3 may be placed on the slide table to position the fixed mold 3 at the first station S1 and the second station S2. Alternatively, a fixed die plate may be provided that faces the movable die plate 12 in the vertical direction, and the fixed mold 3 may be placed on the fixed die plate so that the fixed mold 3 always faces the movable mold 4 in the vertical direction.

[0055] Although embodiments of the present invention have been described above, the present invention is not limited to these examples. For example, the present invention may be applied to molding systems having molding machines other than transfer molding machines, and additions, deletions, and design modifications of components to the above embodiments as appropriate by those skilled in the art, or combinations of features of the embodiments as appropriate, are also included in the scope of the present invention, as long as they do not contradict the spirit of the present invention. [Explanation of Symbols]

[0056] 1... Molding system, 3... Fixed mold, 4... Movable mold, 4a... Upper mold, 4b... Lower mold 5...Automatic machine, 6...Measuring device, 7...Transfer molding machine, 8...Frame, 9...Base, 10…Clip clamping device, 11…Rotary table, 12…Movable die plate, 13...Tailstock, 14...Tie bar, 15...Rotating drive mechanism, 16...Adjustment device, 17...Toggle link mechanism, 20...Injection device, 21...Plunger, 30...Control device, 100... Insert component, 105... Magnet hole, 107... Space, 110...Magnet, 120...Resin part, 200...Product, 300...Adhesive

Claims

1. A clamping device for clamping a fixed mold and a movable mold, A plunger that pushes resin into a space formed in an insert component sandwiched in the thickness direction between the fixed mold and the movable mold, A molding system having a control device for controlling the clamping device, The clamping device, A fixed die plate to which the aforementioned fixed side mold is attached, The movable die is attached to the fixed die plate and the movable die plate facing the clamping direction, The fixed die plate is sandwiched between the movable die plate and the tailstock facing the clamping direction, Multiple tie bars connecting the movable die plate and the tailstock, It has a toggle link mechanism that is positioned between the fixed die plate and the tailstock and is bendable and extendable, The control device, When the toggle link mechanism is bent, the distance between the movable die plate and the tailstock is set to a size corresponding to the thickness of the insert component. A molding system characterized by extending the toggle link mechanism to clamp the fixed mold and the movable mold together.

2. A clamping device for clamping a fixed mold and a movable mold, A plunger that pushes resin into a space formed in an insert component sandwiched in the thickness direction between the fixed mold and the movable mold, A molding system having a control device for controlling the clamping device, The clamping device, A fixed die plate to which the aforementioned fixed side mold is attached, The movable die is attached to the fixed die plate and the movable die plate facing the clamping direction, The movable die plate is sandwiched between the fixed die plate and the tailstock facing the clamping direction, Multiple tie bars connecting the fixed die plate and the tailstock, It has a toggle link mechanism positioned between the movable die plate and the tailstock, which bends and extends, The control device, When the toggle link mechanism is bent, the distance between the fixed die plate and the tailstock is set to a size corresponding to the thickness of the insert component. A molding system characterized by extending the toggle link mechanism to clamp the fixed mold and the movable mold together.

3. The molding system further includes a measuring device for measuring the thickness of the insert component, The molding system according to claim 1 or 2, wherein the control device sets the spacing to a size corresponding to the thickness of the insert part measured by the measuring device.

4. The molding system according to claim 3, wherein the measuring device has a press mechanism for compressing the insert component in the thickness direction, and measures the thickness of the insert component compressed by the press mechanism.

5. The thickness of the insert component is divided into several stages. The intervals are set to be different from each other, corresponding to the aforementioned multiple stages. The control device, One of the multiple steps is obtained, which includes the thickness of the insert part measured by the measuring device. The molding system according to claim 3, wherein the interval is set to the size of the interval corresponding to the first stage.

6. The molding system according to claim 1 or claim 2, wherein the insert component is formed by stacking a plurality of plates in the thickness direction.

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