Injection molding machine system and manufacturing method of molded product

Abstract

To provide an injection molding machine system which can shorten the manufacturing time.SOLUTION: An injection molding machine system (1) includes an injection molding machine (2) having a plurality of mold platens (12, 13, 15) that are mutually mold-clamped, molds (30, 31, ...) provided on the mold platens, and non-contact heating means (3). The molds (30, 31, ...) have parting lines (P1, P2) on two or more surfaces, and two or more cavities (51, 52) for primary molding and one or more cavities (36, 39) for secondary molding are formed by mold-clamping. Primary molded articles (54, 55) having joint end faces (54a, 55a) are injection molded by the cavities (51, 52) for primary molding. A molded article (57) is obtained by putting the primary molded articles into the cavities (36, 39) for secondary molding, melting the joint end faces (54a, 55a) by the non-contact heating means (3), and mold-clamping.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to an injection molding machine system that uses injection molding to produce two or more primary molded products, pairs the primary molded products, and melts and fuses their joining end faces to produce a molded product, and to a method for manufacturing the molded product. [Background technology]

[0002] A pair of primary molded products having joint end surfaces are molded by injection molding. The joint end surfaces of the pair of primary molded products are then melted and fused together to obtain a single molded product. Patent Document 1 describes an injection molding machine system that implements such a manufacturing method for a molded product. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-155775 A

[0004] The injection molding machine system described in Patent Document 1 includes a so-called opposed twin-head injection molding machine and a heater consisting of a halogen heater or a carbon heater. The opposed twin-head injection molding machine includes a clamping device and two injection devices. The clamping device includes a fixed platen fixed to a bed, a movable platen that slides on the bed, and an intermediate platen that is rotatably provided between the fixed platen and the movable platen and slides on the bed. The fixed platen, intermediate platen, and movable platen are each provided with a mold, and when the molds are clamped, the mold on the fixed platen and the mold on the intermediate platen, and the mold on the intermediate platen and the mold on the movable platen are clamped, respectively. In other words, when multiple molds are clamped, cavities are formed at the parting lines on two surfaces. When resin is injected from the injection devices provided on the fixed platen and the movable platen, one primary molded product is molded between the fixed platen and the intermediate platen, and one primary molded product is molded between the movable platen and the intermediate platen.

[0005] The mold is opened, leaving one primary molded product in the fixed platen mold and the other primary molded product in the intermediate platen mold. The intermediate platen is rotated, i.e., inverted, so that the two primary molded products face each other. The amount of opening between the fixed platen and intermediate platen is reduced, and a heater is inserted non-contactingly between the two primary molded products and heated. The two primary molded products have joint end surfaces, which melt. The heater is retracted, and the fixed platen and intermediate platen are clamped together. The two primary molded products are then welded together at their joint end surfaces, and the molded product is obtained. Summary of the Invention [Problem to be solved by the invention]

[0006] The injection molding machine system described in Patent Document 1 can simultaneously obtain two primary molded products at two parting lines during injection molding, and then melt and weld these joint end faces to obtain a molded product. All of these processes can be performed within the injection molding machine system. Therefore, molding efficiency is relatively high and there is no adhesion of dirt to the molded product, which is excellent. However, there is a problem that the manufacturing time is extended because the intermediate platen must be rotated.

[0007] The present disclosure provides an injection molding machine system and a method for manufacturing a molded product that can shorten the manufacturing time.

[0008] Other objects and novel features will become apparent from the description of this specification and the accompanying drawings. [Means for solving the problem]

[0009] The present disclosure relates to an injection molding machine system including an injection molding machine having a plurality of platens that are clamped together, a mold provided on the plurality of platens, and a non-contact heating means. The mold has parting lines on a plurality of surfaces, and when clamped, two or more primary molding cavities and one or more secondary molding cavities are formed. When injection molding is performed in the primary molding cavity, two or more primary molded products having joint end surfaces are molded. A pair of primary molded products are placed in the secondary molding cavity, the joint end surfaces are melted by the non-contact heating means, and when the mold is clamped, a molded product is obtained by welding. Effect of the Invention

[0010] The present disclosure allows for faster production times since there is no need to rotate the platens. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a top view showing an injection molding machine system according to a first embodiment. [Diagram 2] 1 is a front view showing an injection molding machine, a mold, and a heater device according to a first embodiment. [Figure 3A] 1 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a first embodiment is carried out. [Figure 3B] 1 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a first embodiment is carried out. [Figure 3C] 1 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a first embodiment is carried out. [Figure 3D] 1 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a first embodiment is carried out. [Figure 3E] 1 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a first embodiment is carried out. [Figure 3F]1 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a first embodiment is carried out. [Figure 4A] 10 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a second embodiment is carried out. FIG. [Figure 4B] 10 is a front cross-sectional view showing a part of an injection molding machine and a mold in which a manufacturing method for a molded product according to a second embodiment is carried out. FIG. [Diagram 5] FIG. 11 is a front cross-sectional view showing a part of an injection molding machine system according to a third embodiment. [Figure 6A] 11 is a front cross-sectional view showing a part of an injection molding machine system implementing a method for manufacturing a molded product according to a third embodiment. FIG. [Figure 6B] 11 is a front cross-sectional view showing a part of an injection molding machine system implementing a method for manufacturing a molded product according to a third embodiment. FIG. [Figure 6C] 11 is a front cross-sectional view showing a part of an injection molding machine system implementing a method for manufacturing a molded product according to a third embodiment. FIG. [Figure 6D] 11 is a front cross-sectional view showing a part of an injection molding machine system implementing a method for manufacturing a molded product according to a third embodiment. FIG. [Figure 6E] 11 is a front cross-sectional view showing a part of an injection molding machine system implementing a method for manufacturing a molded product according to a third embodiment. FIG. [Figure 6F] 11 is a front cross-sectional view showing a part of an injection molding machine system implementing a method for manufacturing a molded product according to a third embodiment. FIG. [Figure 7] FIG. 13 is a top view showing an injection molding machine system according to a fourth embodiment. [Figure 8] FIG. 11 is a front cross-sectional view showing a part of an injection molding machine system according to a fourth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Specific embodiments will be described in detail below with reference to the drawings. However, the present invention is not limited to the following embodiments. In order to clarify the description, the following description and drawings are appropriately simplified. In each drawing, the same elements are given the same reference numerals, and duplicated descriptions are omitted as necessary. In addition, hatching is omitted in some parts to avoid cluttering the drawings.

[0013] [First embodiment] <Injection molding machine system> As shown in FIG. 1, the injection molding machine system 1 according to the first embodiment is composed of an injection molding machine 2, a heater device 3 arranged in close proximity to the injection molding machine 2, and a conveying device 5 also arranged in close proximity to the injection molding machine 2.

[0014] <Injection molding machine> 1 and 2, the injection molding machine 2 according to the first embodiment is composed of a mold clamping device 7 and first and second injection devices 9 and 10 arranged opposite to each other with respect to the mold clamping device 7. That is, in the first embodiment, the injection molding machine 2 is a so-called opposed twin-head injection molding machine. Therefore, as will be described later, the injection material is injected from the first and second injection devices 9 and 10 substantially simultaneously, so that a plurality of primary molded products can be molded.

[0015] <Mold clamping device> The mold clamping device 7 includes first to third mold platens. That is, the mold clamping device 7 includes a fixed platen 12 of the first mold platen fixed to the bed B, a movable platen 13 of the third mold platen slidably provided on the bed B, and an intermediate platen 15 of the second mold platen slidably provided on the bed B between the fixed platen 12 and the movable platen 13. The fixed platen 12 and the movable platen 13 are connected by a plurality of tie bars 17, 17, ..., which penetrate the intermediate platen 15. To explain in detail with reference to FIG. 2, each of the tie bars 17, 17, ... has a piston portion 18 at one end, which is slidably inserted into a cylinder portion 19 formed in the fixed platen 12, and thereby the one end is connected to the fixed platen 12. The piston portion 18 and the cylinder portion 19 form a mold clamping cylinder 21, which supplies pressure oil to an oil chamber 22 during mold clamping.

[0016] The tie bars 17, 17 have a bolt portion 24 near the other end. The bolt portion 24 is a section in which a plurality of parallel grooves are formed at a constant pitch on the outer circumferential surface of the tie bars 17, 17. Such a bolt portion 24 is inserted into a tie bar hole 23 formed in the movable platen 13, and a part of it penetrates the movable platen 13 and is exposed on the rear side. A pair of half nuts 25, 25 are provided on the rear side of the movable platen 13 so as to be slidable along the rear surface of the movable platen 13. When the pair of half nuts 25, 25 are driven by a mechanism not shown and approach each other, the groove of the bolt portion 24 and the groove on the inner circumferential surface of the half nuts 25, 25 engage with each other. That is, the tie bars 17, 17 and the movable platen 13 are fixedly connected to each other. On the other hand, when this mechanism is driven to separate the pair of half nuts 25, 25, the groove in the bolt portion 24 and the groove on the inner surface of the half nuts 25, 25 are disengaged, and the connection between the movable platen 13 and the tie bars 17, 17 is released.

[0017] The clamping device 7 according to the first embodiment includes a first drive mechanism 27 for opening and closing the movable platen 13, and a second drive mechanism 28 for opening and closing the intermediate platen 15. The first drive mechanism 27 is composed of a ball screw mechanism and an electric servo motor (not shown), and a ball screw 27a of the ball screw mechanism is fixed to a predetermined member fixed to the bed B, and a ball nut 27b is provided rotatably with respect to the movable platen 13. Therefore, when the electric servo motor (not shown) is driven to rotate the ball nut 27b, the movable platen 13 is driven in a direction approaching the fixed platen 12 or in a direction away from the fixed platen 12.

[0018] The second drive mechanism 28 is also composed of a ball screw mechanism and an electric servo motor (not shown), and a ball screw 28a of the ball screw mechanism is fixed to a predetermined member fixed to the movable platen 13, and a ball nut 28b is provided rotatably relative to the intermediate platen 15. Therefore, when the electric servo motor (not shown) is driven to rotate the ball nut 28b, the intermediate platen 15 is driven relative to the movable platen 13. In other words, the intermediate platen 15 is driven in a direction approaching the movable platen 13 or in a direction moving away from the movable platen 13. In this way, the mold clamping device 7 according to this embodiment is configured to open and close the mold by the first and second drive mechanisms 27 and 28.

[0019] When opening and closing the mold, the mold clamping device 7 according to the first embodiment drives the half nuts 25, 25 to release the connection between the tie bars 17, 17 and the movable platen 13. Then, the first and second drive mechanisms 27, 28 are driven to slide the movable platen 13 and the intermediate platen 15. On the other hand, when clamping the mold, the first and second drive mechanisms 27, 28 are driven to drive the movable platen 13 toward the fixed platen 12 and the intermediate platen 15 toward the fixed platen 12. This closes the mold according to the present embodiment described next. Then, the half nuts 25, 25 are driven to connect the half nuts 25, 25, the tie bars 17, 17 and the movable platen 13. Pressure oil is supplied to the oil chamber 22 of the mold clamping cylinder 21. Then, the mold is clamped.

[0020] The clamping device 7 according to the first embodiment includes an intermediate platen 15, so that when the molds are clamped, the molds are clamped between the fixed platen 12 and the intermediate platen 15, and between the intermediate platen 15 and the movable platen 13. Although it is different from a so-called stack mold, it has two parting lines, and the mold clamping force can be applied to the parting lines between the molds simultaneously, which is efficient. However, the intermediate platen 15 does not rotate in this embodiment. Therefore, it is possible to save the time required to turn over the intermediate platen 15 in the molding cycle. Furthermore, there is no need to provide a mechanism for rotating the intermediate platen 15, and there is no risk of deterioration.

[0021] <Mold> As shown in Fig. 2, the mold according to the first embodiment is composed of a fixed mold 30 provided on the fixed platen 12, first and second intermediate molds 31 and 32 provided on the intermediate platen 15, and a movable mold 33 provided on the movable platen 13. The first intermediate mold 31 is opened and closed relative to the fixed mold 30, and the second intermediate mold 32 is opened and closed relative to the movable mold 33. In other words, the fixed mold 30 and the first intermediate mold 31 have a parting line P1, and the movable mold 33 and the second intermediate mold 32 have a parting line P2. When the mold is clamped, the parting lines P1 and P2 on these two surfaces are clamped at the same time.

[0022] The fixed side mold 30 has a first recess 35 and a second recess 36. The first intermediate side mold 31 has a first protrusion 38 and a third recess 39. As will be described later, when the fixed side mold 30 and the first intermediate side mold 31 are clamped, the first recess 35 and the first protrusion 38 form a primary molding cavity for injection molding, and the second recess 36 and the third recess 39 form a secondary molding cavity. The second intermediate side mold 32 has a second protrusion 41, and the movable side mold 33 has a fourth recess 42. As will be described later, when the second intermediate side mold 32 and the movable side mold 33 are clamped, the second protrusion 41 and the fourth recess 42 form a primary molding cavity for injection molding.

[0023] The fixed mold 30 and the movable mold 33 each have a sprue formed on their rear surface, which is in contact with the injection nozzles 9a and 10a of the first and second injection units 9 and 10. The fixed mold 30 and the movable mold 33 each have runners 44 and 45, which communicate with the first recess 35 and the fourth recess 42, respectively.

[0024] <Heater device> The heater device 3 according to the first embodiment is provided near the fixed platen 12, as shown in Figs. 1 and 2. The heater device 3 is composed of a heater 47 and a drive unit 48 that drives the heater 47 to slide back and forth. The heater 47 is a carbon heater or a halogen heater. The heater 47 is supplied with current from a power supply unit (not shown), and reaches 1000°C or higher within a few seconds after current is applied. Therefore, it is possible to melt nearby resin in a non-contact manner in a short time. In other words, the heater device 3 is a non-contact heating means.

[0025] <Transportation equipment> In the first embodiment, the transport device 5 is disposed near the intermediate platen 15 as shown in Fig. 1. The transport device 5 is made up of a robot arm, and as will be described later, serves as transport means for removing the injection-molded primary molded product from the primary molding cavity and transporting it to the secondary molding cavity.

[0026] <Method of manufacturing molded products> A manufacturing method for manufacturing a molded product using an injection molding machine system 1 (see Figs. 1 and 2) will be described. The mold is clamped in the mold clamping device 7 of the injection molding machine 2. That is, the first and second drive mechanisms 27 and 28 (see Fig. 2) are driven to drive the movable platen 13 toward the fixed platen 12 and the intermediate platen 15 toward the fixed platen 12. This closes the fixed side mold 30 and the first intermediate side mold 31, and the second intermediate side mold 32 and the movable side mold 33, respectively. Next, the half nuts 25 and 25 are driven to connect the half nuts 25 and 25 to the tie bars 17 and 17 and the movable platen 13. Pressure oil is supplied to the oil chamber 22 of the mold clamping cylinder 21. This causes the mold clamping device 7 to clamp the mold.

[0027] 3A, a first primary molding cavity 51 is formed from the first recess 35 and the first protrusion 38, and a second primary molding cavity 52 is formed from the second recess 42 and the second protrusion 41. An injection material is injected from the first and second injection devices 9 and 10 to fill the first and second primary molding cavities 51 and 52, and a pair of primary molded products 54 and 55 are molded.

[0028] When the primary molded products 54, 55 have cooled and solidified, the mold clamping device 7 is opened. That is, the supply of pressurized oil to the oil chamber 22 (see FIG. 2) is stopped, and the half nuts 25, 25 are driven to release the connection between the tie bars 17, 17 and the movable platen 13. The first and second drive mechanisms 27, 28 are driven to move the movable platen 13 in a direction away from the fixed platen 12, and the intermediate platen 15 in a direction away from the fixed platen 12, respectively. The state after the mold is opened is shown in FIG. 3B. The primary molded products 54, 55 are left on the first convex portion 38 and the second convex portion 41, respectively.

[0029] The primary molded products 54, 55 are taken out by the conveying device 5 (see FIG. 1) and placed in the second recess 36 and the third recess 39, respectively, as shown in FIG. 3C. These second and third recesses 36, 39 are designed to accommodate the pair of primary molded products and also serve as secondary molding cavities for welding the pair of primary molded products. The pair of primary molded products 54, 55 are formed with joining end faces 54a, 55a, which are end faces for welding the pair of primary molded products to each other. When the pair of primary molded products 54, 55 are placed in the second recess 36 and the third recess 39, the respective joining end faces 54a, 55a face each other.

[0030] In the mold clamping device 7, the first and second drive mechanisms 27 and 28 (see FIG. 2) are driven to drive the intermediate plate 15 in a direction approaching the fixed plate 12, so that the joint end faces 54a and 55a of the primary molded products 54 and 55 (see FIG. 3C) are brought closer to each other. Alternatively, only the second drive mechanism 28 is driven to bring the joint end faces 54a and 55a of the primary molded products 54 and 55 closer to each other. As shown in FIG. 3D, the heater device 3 is driven to insert the heater 47 between the joint end faces 54a and 55a in a non-contact manner. Electricity is applied to the heater 47 to melt the joint end faces 54a and 55a in a non-contact manner. Alternatively, the heater device 3 may be driven first to be positioned between the joint end faces 54a and 55a, and then the first and second drive mechanisms 27 and 28 (see FIG. 2) may be driven to bring the joint end faces 54a and 55a and the heater 47 closer to each other.

[0031] The heater device 3 is driven to move the heater 47 away from the pair of primary molded products 54, 55. The mold is clamped by the mold clamping device 7. Then, as shown in Fig. 3E, the pair of primary molded products 54, 55 are welded together to obtain a molded product 57. At this point, in the first manufacturing method according to the present embodiment, injection material is injected from the first and second injection devices 9, 10 to mold the next pair of primary molded products 54', 55'.

[0032] The mold is opened in the mold clamping device 7. The molded product 57 is taken out by the conveying device 5 (see FIG. 1) as shown in FIG. 3F. The pair of primary molded products 54', 55' are left on the first and second protrusions 38, 41, respectively. As explained with reference to FIG. 3C, the pair of primary molded products 54', 55' are moved to the secondary molding cavity by the conveying device 5. The molded product 57 is manufactured in the same manner. In the manufacturing method of the molded product according to the first embodiment, the welding of the molded product 57, which is the secondary molded product, and the injection molding of the pair of primary molded products 54, 55 are carried out substantially simultaneously. Therefore, one molded product 57 is obtained for each mold clamping. That is, the molded product 57 can be manufactured efficiently.

[0033] [Second embodiment] <Injection molding machine system> The configuration of the injection molding machine system according to the second embodiment is the same as the configuration of the injection molding machine system 1 according to the first embodiment.

[0034] <Method of manufacturing molded products> The manufacturing method of the molded product according to the second embodiment is a modification of the manufacturing method of the molded product according to the first embodiment. In the manufacturing method of the molded product according to the first embodiment, as shown in FIG. 3E, when the molded product 57 is obtained from a pair of primary molded products 54, 55 by clamping the mold, the next pair of primary molded products 54', 55' are molded by injection molding substantially at the same time. However, in the manufacturing method of the molded product according to the second embodiment, as shown in FIG. 4A, when the primary molded products 54, 55 are welded to manufacture the molded product 57, injection molding is not performed. In other words, the primary molded products are not molded at the same time.

[0035] Once molded product 57 is obtained, as shown in Fig. 4B, mold clamping unit 7 is opened and molded product 57 is removed. Next, as shown in Fig. 3A, mold clamping unit 7 is clamped and the next primary molded products 54, 55 are molded by injection molding. Molded products 57 are manufactured in the same manner. In the manufacturing method for molded products according to the second embodiment, it is necessary to perform two mold clamping operations to obtain one molded product 57. However, since the injection molding process for obtaining primary molded products 54, 55 and the process for welding primary molded products 54, 55 are separated, it is possible to obtain high-quality molded product 57.

[0036] [Third embodiment] <Injection molding machine system> The configuration of the injection molding machine system according to the third embodiment is the same as that of the injection molding machine system 1 according to the first embodiment except for the mold and the heater device 3. The mold will be described next. In the third embodiment, two heater devices 3 are provided. However, the two heater devices 3, 3' are configured in the same way, so description thereof will be omitted.

[0037] <Mold> It has been explained that the manufacturing method for a molded product according to the first embodiment can obtain one molded product per clamping. By modifying the mold, it is possible to obtain multiple molded products per clamping. The manufacturing method for a molded product according to the third embodiment can obtain two molded products per clamping. The mold used will now be described.

[0038] 5, the mold according to the third embodiment is composed of a fixed mold 61 provided on the fixed platen 12, first and second intermediate molds 62, 63 provided on the intermediate platen 15, and a movable mold 64 provided on the movable platen 13. That is, parting lines P3, P4 are formed between the fixed mold 61 and the first intermediate mold 62, and between the second intermediate mold 63 and the movable mold 64, respectively. The mold according to the third embodiment is also efficient because the parting lines P3, P4 on these two surfaces are clamped simultaneously during clamping.

[0039] The fixed mold 61 is formed with a first recess 67, a first protrusion 68, and a second recess 69, and the first intermediate mold 62 is formed with a second protrusion 71, a third recess 72, and a fourth recess 73. When the fixed mold 61 and the first intermediate mold 62 are clamped together, the first recess 67 and the second protrusion 71 form a primary molding cavity, and the first protrusion 68 and the third recess 72 form a secondary molding cavity. The second recess 69 and the fourth recess 73 form a secondary molding cavity.

[0040] The second intermediate mold 63 is formed with a third convex portion 75, a fifth concave portion 76, and a sixth concave portion 77, and the movable mold 64 is formed with a seventh concave portion 80, a fourth convex portion 81, and an eighth concave portion 82. When the second intermediate mold 63 and the movable mold 64 are clamped together, a primary molding cavity is formed by the third convex portion 75 and the seventh concave portion 80, and a secondary molding cavity is formed by the fifth concave portion 76 and the fourth convex portion 81. Then, a secondary molding cavity is formed by the sixth concave portion 77 and the eighth concave portion 82.

[0041] <Method of manufacturing molded products> A method for manufacturing a molded product according to the third embodiment will be described. First, the mold clamping device 7 is clamped. The clamped state is shown in Fig. 6A. An injection material is injected from the first and second injection devices 9 and 10 to mold a pair of primary molded products 85 and 86 and another pair of primary molded products 87 and 88.

[0042] The mold clamping device 7 is opened. Then, as shown in Fig. 6B, a pair of primary molded products 85, 86 are left on the first and second convex portions 68, 71, respectively. Similarly, another pair of primary molded products 87, 88 are left on the third and fourth convex portions 75, 81, respectively.

[0043] The conveying device 5 (see FIG. 1) is driven to remove a pair of primary molded products 85, 86 and move them to the secondary molding cavity, i.e., the second and fourth recesses 69, 73, as shown in FIG. 6C. Similarly, another pair of primary molded products 87, 88 is removed and moved to the secondary molding cavity, i.e., the eighth and sixth recesses 82, 77.

[0044] The clamping device 7 is driven to bring the intermediate platen 15 close to the fixed platen 12, and the movable platen 13 close to the intermediate platen 15. Then, a pair of primary molded products 85, 86 and another pair of primary molded products 87, 88 are brought close to each other. As shown in Fig. 6D, the heaters 47, 47' of the heater devices 3, 3' are inserted in a non-contact manner between the pair of primary molded products 85, 86 and between the other pair of primary molded products 87, 88, respectively. Electricity is applied to the heaters 47, 47' to melt the joint end surfaces of the primary molded products 85, 86, 87, 88.

[0045] The heaters 47, 47' are retracted, and the mold clamping device 7 is clamped. Then, two molded products 90, 91 are obtained as shown in Fig. 6E. At this time, the injection material is injected from the first and second injection devices 9, 10 to mold primary molded products 85', 86', 87', 88'. In other words, the production of the molded products 90, 91 and the molding of the primary molded products 85', 86', 87', 88' are carried out substantially simultaneously.

[0046] The mold is opened in the mold clamping device 7. The transfer device 5 (see FIG. 1) is driven to remove the molded products 90 and 91 as shown in FIG. 6F. The primary molded products 85', 86', 87', and 88' remain on the first to fourth protrusions 71, 68, 75, and 81, respectively. As explained with reference to FIG. 6C, these primary molded products 85', 86', 87', and 88' are moved to the secondary molding cavity. Thereafter, the molded products 90 and 91 are manufactured in the same manner.

[0047] [Fourth embodiment] <Injection molding machine system> FIG. 7 shows an injection molding machine system 1' according to a fourth embodiment. In this injection molding machine system 1', an injection molding machine 2' is composed of a clamping device 7' and one injection device 9'. The clamping device 7' has three platens, namely, a fixed platen 12', a movable platen 13', and a clamping housing 95. A toggle mechanism 97 is provided between the movable platen 13' and the clamping housing 95, and a mold 96 according to the fourth embodiment described below is provided between the fixed platen 12' and the movable platen 13'. In other words, this injection molding machine 2' has two platens that are clamped together.

[0048] <Mold> FIG. 8 shows a mold 96 employed in an injection molding machine system 1′ according to a fourth embodiment. The mold 96 according to this embodiment is a so-called stack mold. The mold 96 includes a fixed-side mounting plate 100 attached to a fixed platen 12′, a movable-side mounting plate 101 attached to a movable platen 13′, and an intermediate plate 102. The mold 96 includes first to fourth element molds 105, 106, 107, and 108. The first element mold 105 is fixed to the fixed-side mounting plate 100, the second and third element molds 106 and 107 are fixed to the intermediate plate 102, and the fourth element mold 108 is fixed to the movable-side mounting plate 101.

[0049] The fixed-side mounting plate 100 is provided with a plurality of guide rods 110, 110, and the intermediate plate 102 is provided so as to be slidable by these guide rods 110, 110. In other words, the intermediate plate 102 is adapted to slide in the direction toward and away from the fixed-side mounting plate 100.

[0050] The mold 96 according to the fourth embodiment includes a rack and pinion mechanism 112 for simultaneously opening and closing the first to fourth element molds 105, 106, 107, and 108. The rack and pinion mechanism 112 includes a pinion 114 rotatably provided on the intermediate plate 102, a first rack 115 fixed to the fixed side mounting plate 100, and a second rack 116 fixed to the movable side mounting plate 101. The first and second racks 115 and 116 are engaged with the pinion 114. Therefore, when the movable platen 13' is driven and the movable side mounting plate 101 slides, the intermediate plate 102 slides in conjunction with the movable platen 102. That is, the first to fourth element molds 105, 106, 107, and 108 are opened and closed in conjunction with each other. That is, the mold 96 according to the fourth embodiment also includes parting lines P5 and P6 on two sides, and is clamped at the same time.

[0051] The first element mold 105 has a first recess 135 and a second recess 136. The second element mold 106 has a first protrusion 138 and a third recess 139. The first recess 135 and the first protrusion 138 form a primary molding cavity for injection molding, and the second recess 136 and the third recess 139 form a secondary molding cavity. The third element mold 107 has a second protrusion 141, and the fourth element mold 108 has a fourth recess 142. The second protrusion 141 and the fourth recess 142 form a primary molding cavity for injection molding. Although not described in detail, when the injection material is injected from the injection device 9', the primary molding cavity consisting of the second protrusion 141 and the fourth recess 142 is also filled with the injection material.

[0052] An injection molding machine system 1' (see FIG. 7) equipped with a mold 96 according to the fourth embodiment, which has parting lines P5 and P6 on two sides, can also mold a molded product in a manner similar to the manufacturing method of a molded product according to the first embodiment.

[0053] <Other Modifications> The injection molding machine system 1, 1' and the manufacturing method of the molded product according to the first to fourth embodiments can be modified in various ways. For example, the number of mold platens can be four or more. To increase the number of mold platens to four or more, two or more intermediate plates 15 may be provided. If a mold is provided on each mold platen, a parting line is formed on three or more sides, and the number of cavities for primary molding and the number of cavities for secondary molding can be increased. In this way, three or more molded products can be obtained per one mold clamping. In addition, if two or more intermediate plates are provided in the mold of the fourth embodiment and element molds are provided on each intermediate plate, a parting line is formed on three or more sides, and the number of cavities for primary molding and the number of cavities for secondary molding can be increased. In this way, three or more molded products can be obtained per one mold clamping. Alternatively, even if the number of mold platens is three, the number of molded products that can be manufactured per one mold clamping can be increased by modifying the shape of the mold and increasing the number of cavities.

[0054] Although the invention made by the present inventor has been specifically described above based on the embodiment, it goes without saying that the present invention is not limited to the embodiment already described, and various modifications are possible without departing from the gist of the invention. The above-described examples may be implemented in appropriate combination. [Explanation of symbols]

[0055] 1 Injection molding machine system 2 Injection molding machine 3 Heater device 5 Transport device 7 mold clamping unit 9 first injection unit 10 second injection unit 12 fixed platen 13 Movable plate 15 Intermediate plate 17 Tie bar 18 Piston part 19 Cylinder section 21 Clamping cylinder 22 Oil chamber 23 Tie bar hole 24 Bolt section 25 Half nut 27 First drive mechanism 28 Second drive mechanism 30 fixed side mold 31 first intermediate side mold 32 second intermediate die 33 movable die 35 First recess 36 Second recess 38 First protrusion 39 Third recess 41 second protrusion 42 fourth recess 44 Runner 45 Runner 47 Heater 48 Drive unit 51 First molding cavity 52 Second primary molding cavity 54 Primary molded product 55 Primary molded product 54a Joint end face 55a Joint end face 57 Molded products 61 fixed side mold 62 first intermediate side mold 63 Second intermediate die 64 Movable die 67 First concave portion 68 First convex portion 69 Second concave portion 71 Second convex portion 72 Third recess 73 Fourth recess 75 Third protrusion 76 Fifth recess 77 6th recess 80 7th recess 81 fourth convex portion 82 eighth concave portion 85, 86, 87, 88 Primary molded products 90, 91 Molded products 95 Clamping housing 96 Mold 97 Toggle mechanism 100 Fixed side mounting plate 101 Movable side mounting plate 102 Intermediate plate 105 First element mold 106 Second element mold 107 Third element mold 108 Fourth element mold 110 Guide rod 102 Rack and pinion mechanism 114 Pinion 115 First rack 116 Second Rack 135 First recess 136 Second recess 138 first convex portion 139 third concave portion 141 second protrusion 142 fourth recess B Bed P1, P2, P3, P4, P5, P6 parting lines

Claims

1. an injection molding machine having a plurality of mold plates that are clamped together; A mold provided on the plurality of mold plates; A non-contact heating means, The mold has parting lines on multiple surfaces, and when the mold is closed, at least two or more primary molding cavities and at least one or more secondary molding cavities are formed; When injection molding is performed into the primary molding cavity, a primary molded product having a joining end surface is formed, an injection molding machine system in which a pair of the primary molded products are placed in the secondary molding cavity, and when the joining end surfaces are melted by the non-contact heating means and the molds are closed, a molded product is obtained by welding.

2. 2. The injection molding machine system according to claim 1, further comprising a conveying means configured to convey the primary molded product molded in the primary molding cavity to the secondary molding cavity.

3. 3. The injection molding machine system according to claim 2, wherein the transport means comprises a robot arm.

4. 4. The injection molding machine system according to claim 1, wherein the non-contact heating means comprises a heater that irradiates infrared rays.

5. 5. The injection molding machine system according to claim 1, wherein the plurality of platens include first to third platens, the mold provided between the first platen and the second platen has a parting line on one surface and has one cavity for the primary molding and one cavity for the secondary molding, and the mold provided between the second platen and the third platen has a parting line on another surface and has one cavity for the primary molding.

6. 6. The injection molding machine system according to claim 5, wherein the injection molding machine comprises a first injection device and a second injection device, the first injection device being configured to inject into the primary molding cavity of the mold between the first platen and the second platen, and the second injection device being configured to inject into the primary molding cavity of the mold between the second platen and the third platen.

7. 7. The injection molding machine system according to claim 5, wherein the first to third platens are a fixed platen, an intermediate platen and a movable platen, respectively.

8. 5. The injection molding machine system according to claim 1, wherein when the mold is clamped, two of the primary molding cavities and one of the secondary molding cavities are formed at each of the parting lines on the multiple surfaces.

9. 7. The injection molding machine system according to claim 5 or 6, further comprising a control unit which carries out an injection process of clamping the platens and injecting into the two primary molding cavities to mold a pair of the primary molded products, and a welding process of inserting the pair of primary molded products into the secondary molding cavities, melting the joining end faces by the non-contact heating means, clamping the plates, and welding them to obtain the molded products.

10. 10. The injection molding machine system according to claim 9, wherein the injection molding machine system performs the injection process and the welding process in parallel and substantially simultaneously, and when obtaining the molded product, molds a pair of the primary molded products to be welded next time.

11. 5. The injection molding machine system according to claim 1, wherein the plurality of platens comprises two platens, and the mold comprises a stack mold having parting lines on multiple sides.

12. A manufacturing method for obtaining a molded product by molding a pair of primary molded products having joint end surfaces, melting the joint end surfaces of the pair of primary molded products to weld the joint end surfaces to each other, comprising: The manufacturing method includes: an injection molding machine having a plurality of mold plates that are clamped to each other; A mold provided on the plurality of mold plates; A non-contact heating means is used, The mold has parting lines on a plurality of surfaces, and when the mold is clamped, at least two or more primary molding cavities and at least one or more secondary molding cavities are formed; The manufacturing method includes a molding step of clamping the mold and injecting an injection material into the primary molding cavity to mold a primary molded product; a conveying step of removing the primary molded product from the primary molding cavity and inserting the removed primary molded products in pairs into the secondary molding cavity; a welding process in which the joining end surfaces of the pair of primary molded products placed in the secondary molding cavity are brought close to each other, the non-contact heating means is inserted non-contact to melt the joining end surfaces, the non-contact heating means is withdrawn, and the mold is closed to weld the pair of primary molded products at the joining end surfaces to obtain a molded product.

13. The method for producing a molded product according to claim 12 , wherein the conveying step is performed by a robot arm.

14. The method for producing a molded product according to claim 12 or 13, wherein the non-contact heating means is a heater that irradiates infrared rays.

15. the plurality of platens are first to third platens, the mold provided between the first platen and the second platen has a parting line on one surface and has one cavity for the primary molding and one cavity for the secondary molding, the mold provided between the second platen and the third platen has a parting line on another surface and has one cavity for the primary molding, The molding step includes substantially simultaneously injecting an injection material into the two primary molding cavities to mold a pair of the primary molded products, The method for manufacturing a molded product according to any one of claims 12 to 14, wherein the transport step transports the primary molded products removed from the two primary molding cavities to the secondary molding cavity as a pair of the primary molded products.

16. The method for producing a molded product according to claim 15, wherein the molding step and the welding step are carried out in parallel and substantially simultaneously, and when the molded product is obtained, a pair of the primary molded products to be welded next are molded.

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