Manufacturing methods using shuttle molding and overmolding

Abstract

An injection molding system including injecting resin into a mold and moving the mold between a first position within an injection molding machine and a second position outside the injection molding machine, an improvement to the injection molding system including not moving the first mold until N injection processes have been performed on a first mold by the injection molding machine, moving the first mold from the first position to the second position after the N injection processes on the first mold, and moving an external second mold into the injection molding machine, and inserting a first molded product obtained based on the N injection processes on the first mold into the second mold, and injecting resin into the second mold with the first molded product inserted to obtain a second molded product.

Description

[Technical field]

[0001] The present invention relates to manufacturing methods using shuttle molding and overmolding. CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 196096, filed June 2, 2021, and U.S. Provisional Application No. 63 / 282099, filed November 22, 2021. Technical Field

[0002] The present disclosure relates to an injection molding system. Background technology

[0003] The manufacturing of molded products using an injection molding machine involves injecting resin into a mold after clamping, forcing the resin into the mold at high pressure to compensate for the volume loss caused by the solidification of the resin, holding the molded product in the mold until the resin solidifies, and removing the molded product from the mold. The injection molding process is repeated to obtain the desired number of molded products. After a certain number of moldings are performed with one mold, the mold is ejected from the injection molding machine, the next mold is prepared and inserted into the injection molding machine, and the specified number of injection moldings are performed with the next mold.

[0004] In the above-mentioned molding method, a method of using two molds for one injection molding machine has been proposed. For example, U.S. Patent No. 2018 / 0009146 / JP Patent Publication No. 2018-001738 / VN20160002505 discusses a system in which a conveying device is arranged on both sides of an injection molding machine. FIG. 1 shows the injection molding system of U.S. Patent No. 2018 / 0009146 / JP Patent Publication No. 2018-001738 / VN20160002505. In this system, a mold is moved between a molding operation position where resin is injected and a molded product is removed, and a cooling position where the resin injected into the mold is cooled.

[0005] The injection molding system in US 2018 / 0009146 / JP 2018-001738 / VN20160002505 does not discuss an injection molding process known as overmolding, which is a multi-step injection molding process in which two or more components are molded on top of one another.

[0006] There is a need for a shuttle molding injection system that allows for overmolding. Summary of the Invention

[0007] An injection molding system comprising an injection molding machine that injects resin into a mold, a transport device configured to move the mold between a first position within the injection molding machine and a second position outside the injection molding machine, a controller, and an insertion unit, and an improvement to the injection molding system includes the controller configured to control the transport device so as not to move the first mold until the injection molding machine has performed N injection processes on a first mold (N≧2), the controller being further configured to control the transport device to move the first mold from the first position to the second position after the N injection processes on the first mold and to move a second mold outside the injection molding machine into the injection molding machine, and the insertion unit configured to insert one of the first molded products obtained based on the N injection processes on the first mold into the second mold, and to inject resin into the second mold with the first molded product inserted by the injection molding machine to obtain a second molded product. [Brief description of the drawings]

[0008] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate various embodiments, objects, features, and advantages of the present disclosure.

[0009] FIG. 1 shows an injection molding system.

[0010] FIG. 2 is a side view of the injection molding machine.

[0011] FIG. 3 is an end view of the stationary platen.

[0012] 4A to 4K show a flowchart illustrating the molding process.

[0013] 5A-5R illustrate the molding process in one exemplary embodiment.

[0014] 6A to 6F show a flowchart illustrating the molding process.

[0015] 6G-6I show an improvement to the molding process in FIGS. 6A-6F.

[0016] 7A-7AO illustrate the molding process of one exemplary embodiment.

[0017] Throughout the drawings, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components, or portions of the illustrated embodiments. The present disclosure will now be described in detail with reference to the drawings, in which: FIG. 1 is a block diagram of a semiconductor device according to an embodiment of the present invention; FIG. 2 is a block diagram of a semiconductor device according to an embodiment of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] This disclosure describes several embodiments and relies on patents, patent applications, and other references for details known to those skilled in the art. Thus, when patents, patent applications, or other references are cited or repeated in this specification, they should be understood to be incorporated by reference in their entirety for all purposes, not just as proposed herein.

[0019] An injection molding system according to an embodiment of the present disclosure will be described with reference to the drawings. In each drawing, arrows X and Y indicate horizontal directions that are perpendicular to each other, and arrow Z indicates a vertical (upright) direction relative to the ground.

[0020] 1-3 show an injection molding system 1 of U.S. Patent No. 2018 / 0009146 / JP Patent Publication No. 2018-001738 / VN20160002505 and are provided herein for informational / illustrative purposes only.

[0021] The injection molding system 1 includes an injection molding machine 2, conveying devices 3A and 3B, and a control device 4. The injection molding system 1 uses conveying devices 3A and 3B for one injection molding machine 2 to manufacture molded products while replacing multiple molds. Two molds 100A and 100B are used.

[0022] The molds 100A / 100B are a set of a fixed mold 101 and a movable mold 102 that opens and closes relative to the fixed mold 101. A molded product is molded by injecting molten resin into a cavity formed between the fixed mold 101 and the movable mold 102. Mounting plates 101a and 102a are fixed to the fixed mold 101 and the movable mold 102, respectively. The mounting plates 101a and 102a are used to fix the molds 100A / 100B to a molding operation position 11 (mold clamping position) of the injection molding machine 2.

[0023] The mold 100A / 100B is provided with a self-closing portion 103 that maintains the space between the fixed mold 101 and the movable mold 102 in a closed state. The self-closing portion 103 makes it possible to prevent the mold 100A / 100B from opening even after the mold 100A / 100B is removed from the injection molding machine 2. The self-closing portion 103 maintains the mold 100A / 100B in a closed state by utilizing a magnetic force. The self-closing portion 103 is disposed at a plurality of locations along the opposing surfaces of the fixed mold 101 and the movable mold 102. The self-closing portion 103 is a combination of an element on the fixed mold 101 side and an element on the movable mold 102 side. Usually, two or more sets of self-closing portions 103 are provided for each of the molds 100A and 100B.

[0024] The conveying device 3A carries the mold 100A into and out of the molding operation position 11 of the injection molding machine 2. The conveying device 3B carries the mold 100B into and out of the molding operation position 11. The conveying device 3A, the injection molding machine 2, and the conveying device 3B are arranged in this order in the X-axis direction. In other words, the conveying device 3A and the conveying device 3B are arranged laterally with respect to the injection molding machine 2 so as to sandwich the injection molding machine 2 in the X-axis direction. The conveying devices 3A and 3B are arranged opposite each other, with the conveying device 3A being adjacent to one of the left and right sides of the injection molding machine 2 and the conveying device 3B being adjacent to the other side. The molding operation position 11 is located between the conveying device 3A and the conveying device 3B. Each of the conveying devices 3A and 3B includes a frame 30, a conveying unit 31, a plurality of rollers 32, and a plurality of rollers 33.

[0025] The frame 30 is the skeleton of the transport devices 3A and 3B, and supports the transport unit 31 and a number of rollers 32 and 33. The transport unit 31 is a device that moves the mold 100A / 100B back and forth in the X-axis direction and ejects and inserts the mold 100A / 100B into and from the molding operation position 11.

[0026] The transport unit 31 is an electric cylinder driven by a motor, and includes a rod that advances and retreats relative to the cylinder. The cylinder is fixed to the frame 30, and the fixed mold 101 is fixed to the end of the rod. The transport unit 31 can be either a fluid actuator or an electric actuator, but the electric actuator can improve the control accuracy of the position and speed of the mold 100A / 100B when transporting it. Examples of the fluid actuator include a hydraulic cylinder and an air cylinder. Examples of the electric actuator include, in addition to the electric cylinder, a rack and pinion mechanism driven by a motor, a ball screw mechanism driven by a motor, and the like.

[0027] The transport unit 31 is disposed independently for each of the transport devices 3A and 3B. However, a common support member may be used to support the molds 100A and 100B, and a single common transport unit 31 may be disposed for this support member. When the transport unit 31 is disposed independently for each of the transport devices 3A and 3B, it becomes possible to deal with cases where the movement strokes of the molds 100A and 100B during transport are different. For example, there are cases where the molds cannot be transported simultaneously because their widths (width in the X direction) or thicknesses (width in the Y direction) are different.

[0028] The rollers 32 form a roller row arranged in the X-axis direction, and are arranged in two rows spaced apart in the Y-axis direction. The rollers 32 rotate around a rotation axis in the Z-axis direction, and contact the side surfaces (side surfaces of the mounting plates 101a and 102a) of the mold 100A / 100B to support the mold 100A / 100B from the side and guide the movement of the mold 100A / 100B in the X-axis direction. The rollers 33 form a roller row arranged in the X-axis direction, and are arranged in two rows spaced apart in the Y-axis direction. The rollers 33 rotate around a rotation axis in the Y-axis direction, and support the bottom surface (bottom surfaces of the mounting plates 101a and 102a) of the mold 100A / 100B to support the mold 100A / 100B from below, smoothing the movement of the mold 100A / 100B in the X-axis direction.

[0029] The control device 4 includes a controller 41 for controlling the injection molding machine 2, a controller 42A for controlling the conveying device 3A, and a controller 42B for controlling the conveying device 3B. Each of the controllers 41, 42A, and 42B includes, for example, a processor such as a CPU, a storage device such as a RAM, a ROM, and a hard disk, and an interface (not shown) connected to a sensor or an actuator. The processor executes a program stored in the storage device. An example of a program (control) executed by the controller 41 will be described later. The controller 41 is communicably connected to the controllers 42A and 42B, and instructs the controllers 42A and 42B regarding the conveyance of the molds 100A / 100B. When the loading or unloading of the molds 100A / 100B is completed, the controllers 42A and 42B transmit an operation completion signal to the controller 41. Furthermore, the controllers 42A and 42B transmit an emergency stop signal to the controller 41 when an abnormality occurs.

[0030] Although a controller is provided for each of the injection molding machine 2, the conveying device 3A, and the conveying device 3B, one controller may control all three devices. To ensure more reliable cooperative operation, the conveying devices 3A and 3B may be controlled by a single controller.

[0031] Fig. 2 is a side view of the injection molding machine 2. Fig. 3 is an end view of the fixed platen 61, as seen from the direction of the arrow along line II in Fig. 2.

[0032] 1 and 2, injection molding machine 2 includes an injection device 5, a mold clamping device 6, and a remover 7 that removes a molded product. Injection device 5 and mold clamping device 6 are arranged on frame 10 in the Y-axis direction.

[0033] The injection device 5 includes an injection cylinder 51 arranged to extend in the Y-axis direction. The injection cylinder 51 includes a heating device (not shown) such as a band heater, and melts the resin introduced from a hopper 53. A screw 51a is built into the injection cylinder 51, and the resin introduced into the injection cylinder 51 is plasticized and measured by rotating the screw 51a. The molten resin can be injected from the injection nozzle 52 by moving the screw 51a in the axial direction (Y-axis direction).

[0034] Fig. 2 shows an example of a shutoff nozzle as the nozzle 52. A pin 56a that opens and closes the discharge port 52a is arranged as the opening and closing mechanism 56 in Fig. 2. The pin 56a is connected to an actuator (cylinder) 56c via a link 56b, and the discharge port 52a is opened and closed by the operation of the actuator 56c.

[0035] The injection cylinder 51 is supported by a drive unit 54. The drive unit 54 includes a motor that rotates the screw 51a to plasticize and measure the resin, and a drive motor that moves the screw 51a forward and backward in the axial direction. The drive unit 54 can move forward and backward in the Y-axis direction along rails 12 on the frame 10. The drive unit 54 also includes an actuator (e.g., an electric cylinder) 55 that moves the injection device 5 forward and backward in the Y-axis direction.

[0036] The mold clamping device 6 clamps and opens / closes the mold 100A / 100B. In the mold clamping device 6, a fixed platen 61, a movable platen 62, and a movable platen 63 are arranged in this order in the Y-axis direction. A plurality of tie bars 64 pass through the platens 61 to 63. Each tie bar 64 is a shaft extending in the Y-axis direction, and one end of the tie bar 64 is fixed to the fixed platen 61. Each tie bar 64 is inserted into a through hole formed in the movable platen 62. The other end of each tie bar 64 is fixed to the movable platen 63 via an adjustment mechanism 67. The movable platens 62 and 63 are movable in the Y-axis direction along rails 13 on the frame 10, and the fixed platen 61 is fixed to the frame 10.

[0037] A toggle mechanism 65 is disposed between the movable platen 62 and the movable platen 63. The toggle mechanism 65 moves the movable platen 62 forward and backward in the Y-axis direction relative to the movable platen 63 (in other words, relative to the fixed platen 61). The toggle mechanism 65 includes links 65a to 65c. The link 65a is rotatably connected to the movable platen 62. The link 65b is rotatably connected to the movable platen 63. The links 65a and 65b are rotatably connected to each other. The links 65c and 65b are rotatably connected to each other. The link 65c is rotatably connected to an arm 66c.

[0038] The arm 66c is fixed to a ball nut 66b. The ball nut 66b engages with a ball screw shaft 66a extending in the Y-axis direction, and moves forward and backward in the Y-axis direction by rotation of the ball screw shaft 66a. The ball screw shaft 66a is supported by the movable platen 63 so as to be rotatable, and the motor 66 is supported by the movable platen 63. The motor 66 rotates the ball screw shaft 66a while detecting the amount of rotation of the motor 66. By driving the motor 66 while detecting the amount of rotation of the motor 66, it is possible to clamp and open / close the mold 100A / 100B.

[0039] The injection molding machine 2 includes sensors 68 for measuring the clamping force. Each sensor 68 is, for example, a strain gauge provided on the tie bar 64, and detects the strain of the tie bar 64 to calculate the clamping force.

[0040] The adjustment mechanism 67 includes a nut 67b rotatably supported on the movable platen 63, a motor 67a serving as a drive source, and a transmission mechanism that transmits the drive force of the motor 67a to the nut 67b. Each tie bar 64 passes through a hole formed in the movable platen 63 and engages with the nut 67b. By rotating the nut 67b, the engagement position between the nut 67b and the tie bar 64 in the Y-axis direction changes. In other words, the fixed position of the movable platen 63 relative to the tie bar 64 changes. This makes it possible to change the gap between the movable platen 63 and the fixed platen 61, thereby making it possible to adjust the mold clamping force, etc.

[0041] The forming operation position 11 is the area between a fixed platen 61 and a movable platen 62 .

[0042] The mold 100A / 100B introduced into the molding operation position 11 is sandwiched between a fixed platen 61 and a movable platen 62, thereby clamping the mold. By the movement of the movable platen 62, the movable mold 102 is opened and closed based on the movement of the movable platen 62.

[0043] The ejector 7 includes a rail 71 extending in the X-axis direction and a movable rail 72 movable in the X-axis direction on the rail 71. The movable rail 72 is installed to extend in the Y-axis direction, and a slider 73 is provided on the movable rail 72. The slider 73 has a function of moving in the Y-axis direction while being guided by the movable rail 72, and a function of raising and lowering the lifting shaft 73a in the Z-axis direction. A vacuum head 74 is provided at the lower end of the lifting shaft 73a, and a chuck plate 75 specialized for molded products is attached to the vacuum head 74. After opening the mold, the ejector 7 moves the vacuum head 74 between the fixed mold 101 and the movable mold 102 by the rail 71, the movable rail 72, and the slider 73, as shown by the dashed line in FIG. 2, and adsorbs the molded product and transports it to the outside of the injection molding machine 2. In another exemplary embodiment, the ejector is of a type that mechanically grips the molded product.

[0044] FIG. 3 shows an opening 61a at the center of the fixed platen 61, through which the nozzle 52 advances and retreats. A plurality of rollers BR are supported rotatably on the surface (called the inner surface) of the fixed platen 61 facing the movable platen 62. The rollers BR rotate about their rotation axes in the Y-axis direction, support the bottom surface (the bottom surface of the mounting plate 101a) of the mold 100A / 100B, and support the mold 100A / 100B from below to facilitate the movement of the mold 100A / 100B in the X-axis direction. Roller supports 620 are fixed to both sides of the fixed platen 61 in the X-axis direction, and the roller supports 620 support the rollers BR. A groove 61b extending in the X-axis direction is formed on the inner surface of the fixed platen 61.

[0045] The grooves 61b are formed in two rows spaced apart from each other vertically. A roller unit 640 is disposed in each groove 61b. A plurality of rollers SR are supported in the roller unit 640 so as to be rotatable. The rollers SR rotate in the Z-axis direction around a rotation axis and contact the outer surface (the outer surface of the mounting plate 101a) of the mold 100A / 100B to support the mold 100A / 100B from the side and guide the movement of the mold 100A / 100B in the X-axis direction. As shown in the cross-sectional view of line II-II, the roller unit 640 is biased by a spring 641 to a position where the rollers SR protrude from the groove 61b, while when the mold is clamped, the rollers SR retract into the groove 61b to a position where they do not protrude from the groove 61b. The roller unit 640 can prevent damage to the inner surface of the fixed platen 61 due to contact between the mold 100A / 100B and the inner surface of the mold 100A / 100B when replacing the mold 100A / 100B, and does not prevent the inner surface of the fixed platen 61 and the mold 100A / 100B from coming into close contact with each other when clamping the mold. Roller supports 630 are fixed to both sides in the X-axis direction of the fixed platen 61, and a plurality of rollers SR are supported by the roller supports 630.

[0046] A plurality of fixing mechanisms (clamps) 610 for fixing the stationary mold 101 to the stationary platen 61 are arranged on the stationary platen 61. Each fixing mechanism 610 includes an engagement portion 610a that engages with the mounting plate 101a, and a built-in actuator (not shown) that moves the engagement portion 610a between an engaged position and a disengaged position.

[0047] As with the fixed platen 61, the movable platen 62 also includes a plurality of rollers BR, roller supports 620 and 630, a roller unit 640, and a fixing mechanism 610 for fixing the movable mold 102.

[0048] 4A-4K show an example of the operation of the injection molding system 1 performed by the controller 41 in this embodiment. Included in FIG. 4A-4K are steps that are known injection molding functions and steps that are improvements to these known functions. The known functions are included to provide a detailed description of the embodiment. For purposes of explanation, the steps related to these improvements will be shown as improvements. The following example shows a case where a molding operation is performed while swapping between molds 100A and 100B.

[0049] In step S1, initial settings are performed. The operating conditions of the injection unit 5 and the clamping unit 6 are registered for both the molds 100A and 100B. The operating conditions include, but are not limited to, the amount of resin injected per injection, the temperature, the injection speed, the clamping force, and the initial value of the position of the movable platen 63 relative to the tie bars 64. These operating conditions are different even if the molds 100A and 100B are the same type of molds. Since the mold 100A is used for the first molding operation, the conditions related to the mold 100A are automatically set as the operating conditions. In addition, heating of the injection cylinder 51 and plasticization and metering of the initial resin are started.

[0050] As described later, even in the case of the operating conditions of the mold 100A, the operating conditions for molding the primary molded product may differ from the operating conditions for molding the primary molded product and the tertiary molded product. In step S1, the controller 41 sets, based on a user input, an operating condition A for molding the primary molded product "n" using the mold 100A, an operating condition B for molding the secondary molded product "y" using the mold 100B, and an operating condition C for molding the primary molded product "n" and the tertiary molded product "x" using the mold 100A.

[0051] In step S2, the mold 100A is transported into the injection molding machine 2. The motor 66 is driven to make the gap between the fixed platen 61 and the movable platen 62 slightly wider than the thickness (width in the Y direction) of the mold 100A. Next, the controller 41 transmits an instruction to carry in the mold 100A to the controller 42A, and the controller 42A drives the transport unit 31 to carry in the mold 100A to the molding operation position 11. At the same time as carrying in the mold 100A, the mold 100B is carried out. When carrying in of the mold 100A is completed, a signal indicating the completion of carrying in is transmitted from the controller 42A to the controller 41. When the signal indicating the completion of carrying in is received, the motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100A. At this time, it is not necessary to generate a clamping force that is generated during molding. The fixing mechanism 610 is driven to lock the mold 100A to the fixed platen 61 and the movable platen 62, respectively.

[0052] In step S3, the motor 66 is driven to drive the toggle mechanism 65, and the mold 100A is clamped by the fixed platen 61 and the movable platen 62. In step S4, preparations for injection into the mold 100A are made. The actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100A.

[0053] In step S5, the molten resin is injected and pressure is maintained. More specifically, the injection device 5 is driven to fill the cavity in the mold 100A with the molten resin from the nozzle 52, and the resin in the cylinder 51 is pushed into the mold 100A at high pressure to compensate for the volume reduction caused by the solidification of the resin. The actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand, which may result in a difference between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68.

[0054] The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bars 64. In this way, the accuracy of the clamping force can be improved by adjusting the clamping force by correcting the initial value of the position of the movable platen 63 relative to the tie bars 64 based on the measurement results of the sensor 68. The position adjustment of the movable platen 63 relative to the tie bars 64 may be performed at any timing.

[0055] In step S6, timing of the cooling time of the molded part in the mold 100A is started. In step S12, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time started in step S6 has reached a predetermined time. If the cooling is completed, the processes of steps S13 and S15 are performed in parallel with step S14. As will be described later, step S12 is an improvement of the injection molding operation because the cooling is performed before moving / ejecting the mold 100A.

[0056] The first primary molded product is molded through the above-mentioned steps of injection preparation (S4), injection pressure hold (S5), and cooling (time measurement start and completion determination) (S6, S12). Although not shown in Fig. 4A, the cooling process of the injected resin is performed from the start of cooling time measurement in step S6 to the completion determination in step S12, and is a process of cooling the molten resin in the mold by a temperature regulator (not shown) connected to the mold 100A or air supplied from outside the injection molding system 1.

[0057] Steps S13 to S122 in FIG. 4B show an improvement of the injection molding operation. In step S13, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. The movable mold 102 is separated from the fixed mold 101, and the mold 100A is opened. In step S14, the ejector 7 is driven to eject the first primary molded product remaining on the movable mold 102 side of the mold 100A, and transport it to the outside of the injection molding system 1. The vacuum head 74 moves to a position where the chuck plate 75 faces the molded product P, and holds the molded product P there by suction force. The ejector 7 continues to hold the first primary molded product until the first primary molded product is inserted (placed) in the mold 100B, as described later.

[0058] In step S15, the motor 66 is driven to move the movable platen 62 toward the fixed platen 61. This brings the movable mold 102 into close contact with the fixed mold 101, and the mold 100A is closed.

[0059] In step S16, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100A. In step S17, preparations for injection into the mold 100A are made. This includes measuring the amount of resin. When the nozzle 52 is away from the mold 100A, the actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100A.

[0060] In step S18, the molten resin is injected and pressure is maintained. The injection in step S18 is for molding a second primary molded product having the same shape as in step S5.

[0061] More specifically, the injection unit 5 is driven to fill the cavity in the mold 100A with molten resin from the nozzle 52, and the resin is forced into the mold 100A at high pressure to compensate for the volume loss caused by the solidification of the resin. During the process of step S18, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand. In some cases, a difference occurs between the initial clamping force and the clamping force after a certain amount of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68.

[0062] The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bars 64. In this way, the accuracy of the clamping force can be improved by adjusting the clamping force by correcting the initial value of the position of the movable platen 63 relative to the tie bars 64 based on the measurement results of the sensor 68. The position adjustment of the movable platen 63 relative to the tie bars 64 may be performed at any timing.

[0063] In step S66, timing of the cooling time of the molded product in the mold 100A starts.

[0064] In step S122, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time that was started in step S66 has reached a predetermined time. If the cooling is completed, the processes of steps S133 and S155 are performed in parallel with step S144.

[0065] The second primary molded product is molded through the above-mentioned steps of injection preparation (S4), injection pressure hold (S5), and cooling (time measurement start and completion determination) (S66, S122). In this embodiment, the first and second primary molded products are molded products of similar materials and shapes. Although not shown, the cooling process of the injected resin is performed from the start of cooling time measurement in step S66 to the completion determination in step S122, where the molten resin in the mold is cooled by a temperature regulator (not shown) connected to the mold 100A or air supplied from outside the injection molding system 1.

[0066] Steps S133 to S188 in Fig. 4C show an improvement to the injection molding operation. In step S133, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. Since the fixed mold 101 is fixed to the fixed platen 61 by the fixing mechanism 610 and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610, the movable mold 102 is separated from the fixed mold 101, and the mold 100A is opened.

[0067] In step S144, the ejector 7 is driven to eject the second primary molded product remaining on the movable mold 102 side (inside the cavity) of the mold 100A, and transports it to the upper region of the molding machine 2 and holds it in a standby state. The vacuum head 74 moves to a position where the chuck plate 75 faces the molded product P, and holds the molded product P by suction force. The ejector 7 continues to hold the second primary molded product until it is inserted (placed) in the mold 100B, as described below.

[0068] In step S155, the motor 66 is driven to move the movable platen 62 closer to the fixed platen 61. This brings the movable mold 102A into close contact with the fixed mold 101A, and the mold 100A is closed.

[0069] In step S166, motor 66 is driven to drive toggle mechanism 65, and mold 100A is clamped by fixed platen 61 and movable platen 62. In step S177, preparation for injection into mold 100A is performed. Here, resin is measured. Actuator 55 is driven to move injection unit 5, and nozzle 52 is brought into contact with mold 100A.

[0070] In step S188, the molten resin is injected and pressure is maintained. The injection in step S188 is for molding a third primary molded product having the same shape as in step S5.

[0071] More specifically, the injection unit 5 is driven to fill the cavity in the mold 100A with molten resin from the nozzle 52, and the resin in the cylinder 51 is forced into the mold 100A at high pressure to compensate for the volume loss caused by the solidification of the resin. During the processing of step S188, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand, and in some cases, a difference occurs between the initial clamping force and the clamping force after some time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68.

[0072] The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bars 64. In this way, the accuracy of the clamping force can be improved by adjusting the clamping force by correcting the initial value of the position of the movable platen 63 relative to the tie bars 64 based on the measurement results of the sensor 68. The position adjustment of the movable platen 63 relative to the tie bars 64 may be performed at any timing.

[0073] Next, the processes of steps S19 and S21 are performed in parallel with step S20. In step S19, timing of the cooling time of the molded product in the mold 100A is started. In step S20, processes related to the mold clamping device 6 are performed. First, the lock of the mold 100A by the fixing mechanism 610 is released. After a predetermined time delay from step S188, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space that allows the mold to be replaced.

[0074] In step S21, processing related to the injection unit 5 is performed. Here, for example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed. Pressure holding suck back and nozzle shutoff are performed to prevent the molten resin from dripping when the nozzle 52 is separated from the mold 100A. These processing can be performed during the delay time before the movable platen 62 is slightly separated from the fixed platen 61. Pressure holding suck back is performed by retracting the screw 51a after pressure holding to reduce the resin pressure in the injection cylinder 51 and the mold 100A. Nozzle shutoff is performed by closing the discharge port 52a of the nozzle 52. The above operations make it possible to suppress the leakage of resin.

[0075] Through the above steps of injection preparation (S17 / S177), injection pressure hold (S18 / S188), and cooling (timing start and completion determination), the second and third primary molded products are molded. Although not shown, the cooling process of the injected resin is carried out between the start of cooling time measurement in step S19 and the completion determination in step S22, and is a process of cooling the molten resin in the mold by a temperature regulator (not shown) connected to the mold 100A or by air outside the injection molding system 1.

[0076] At least a part of the cooling process of the mold 100A is performed on the transport device 3A, not at the molding operation position 11. The cooling process of the mold 100A is performed in parallel with at least a part of the process from the replacement of the mold in S22 to the replacement of the mold in S34, for example, removal of molded product A from the mold 100B at the molding operation position 11 (S1444) and arrangement of the primary molded product (S26, S266), which will be described later.

[0077] In step S22, the molds 100A and 100B are replaced. The mold 100A is carried out from the molding operation position 11 to the conveying device 3A, and the mold 100B is carried from the conveying device 3B to the molding operation position 11. The controller 41 transmits an instruction to the controller 42A to carry out the mold 100A, and the controller 42A drives the conveying unit 31 to carry out the mold 100A from the molding operation position 11. When the carrying out is completed, the controller 42A transmits a signal indicating the carrying out completion to the controller 41. The mold 100A is cooled on the conveying device 3A. The closed state of the mold 100A is maintained by the self-closing portion 103.

[0078] When a signal indicating completion of loading is received, in step S23, conditions related to the mold 100B are set as the operating conditions for the molding operation. The controller 41 reads out and sets operating condition B from the multiple operating conditions (operating conditions A, B, and C) set in step S1. For example, the thickness (width in the Y direction) of the mold 100B, mold clamping force, etc. are set as the operating conditions for this molding. In addition, operating conditions such as the injection speed corresponding to the mold 100B are also set. Plasticization metering for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100B. At this time, it is not necessary to generate a mold clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100B to the fixed platen 61 and the movable platen 62, respectively.

[0079] In this embodiment, step S23 is performed after step S22. In another exemplary embodiment, since it may take time to switch the operating conditions, for example, the operating conditions may be switched simultaneously with the instruction to unload the mold 100A.

[0080] In step S25, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. The movable mold 102 is separated from the fixed mold 101, and the mold 100B is opened.

[0081] Steps S26 to S30 in Fig. 4D show an improvement to the injection molding operation. In step S26, similar to step S14, the ejector 7 is driven to insert (place) the first primary molded product on the movable mold side of the mold 100B. In step S27, the motor 66 is driven to move the movable platen 62 toward the fixed platen 61. This brings the movable mold 102 into close contact with the fixed mold 101, and the mold 100B is closed.

[0082] In step S28, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100B. In step S29, preparations for injection into the mold 100B are made. Here, the actuator 55 is driven to move the injection device 5, and the nozzle 52 is brought into contact with the mold 100B. The molding of the secondary molded product α is performed in a state in which the first primary molded product is placed in the mold 100B, and in steps S29 to S33 and S36, the resin is injected into the first primary molded product to be integrated, thereby performing overmolding. In this embodiment, the resin injected to mold the secondary molded product α is a different type of resin from the resin injected to mold the primary molded product. The cooling process of the injected resin is carried out from the start of measuring the cooling time in step S666 to the completion determination in step S1222, and is a process in which the molten resin in the mold is cooled using a temperature regulator (not shown) connected to mold 100B or air supplied from outside the injection molding system 1.

[0083] In step S30, the molten resin is injected and pressure is maintained. More specifically, the injection device 5 is driven to fill the cavity in the mold 100B with the molten resin from the nozzle 52, and in order to compensate for the volume reduction caused by the solidification of the resin, the resin in the cylinder 51 is forced into the mold 100B at high pressure. In this way, the first primary molded product is overmolded to form a secondary molded product α. During the processing of step S30, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100B gradually increases, causing the mold 100B to thermally expand, which may cause a difference between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, by correcting the initial value of the position of the movable platen 63 relative to the tie bars 64 based on the measurement results of the sensor 68 and adjusting the clamping force, it is possible to improve the accuracy of the clamping force.

[0084] In step S666, timing of the cooling time of the molded product in the mold 100B begins.

[0085] In step S1222, it is determined whether the cooling of the mold 100B is completed based on whether the cooling time measurement started in step S666 has reached a predetermined time. If the cooling is completed, the processes from step S1333 to step S1555 and the process of step S1444 are performed in parallel.

[0086] The molding of the secondary molded product α is performed in each of the steps of the above-mentioned injection preparation (S29), injection pressure hold (S30), and cooling (timing start and completion determination) (S666, S1222). The cooling process of the injected resin is performed from the start of cooling time measurement in step S666 to the completion determination in step S1222, and is a process of cooling the molten resin in the mold by a temperature regulator (not shown) connected to the mold 100B or air supplied from outside the injection molding system 1.

[0087] In step S1333, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. As a result, the movable mold 102 is separated from the fixed mold 101, and the mold 100B is opened.

[0088] Steps S266 to S1888 in FIG. 4E show an improvement of the injection molding operation. In step S1444, the ejector 7 is driven to eject the secondary molded product α remaining on the movable mold 102 side (inside the cavity) of the mold 100B, and transport it to the upper area of ​​the injection molding machine 2 and hold it in a standby state. The vacuum head 74 moves to a position where the chuck plate 75 faces the secondary molded product α, and holds the secondary molded product α by suction force. The ejector 7 continues to hold the secondary molded product α from the ejection step (S1444) until the secondary molded product α is inserted (placed) into the mold 100A (S26666), which will be described later.

[0089] In step S1555, the motor 66 is driven to move the movable platen 62 closer to the fixed platen 61. As a result, the separated movable mold 102 is brought into close contact with the fixed mold 101 again, and the mold 100B is closed.

[0090] In step S1666, motor 66 is driven to drive toggle mechanism 65, and mold 100B is clamped by fixed platen 61 and movable platen 62. In step S1777, preparation for injection into mold 100B is performed. Here, resin is measured. Actuator 55 is driven to move injection unit 5, and nozzle 52 is brought into contact with mold 100B.

[0091] In step S1888, molten resin is injected and pressure is maintained. The injection in step S1888 is for molding a secondary molded product β having the same shape as in step S29.

[0092] More specifically, the injection unit 5 is driven to fill the cavity in the mold 100B with molten resin from the nozzle 52, and the resin in the cylinder 51 is forced into the mold 100B at high pressure to compensate for the volume reduction caused by the solidification of the resin. When processing step S1888, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100B gradually increases, causing the mold 100B to thermally expand. In some cases, a difference occurs between the initial clamping force and the clamping force after a certain amount of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, the initial value of the position of the movable platen 63 relative to the tie bar 64 is corrected according to the measurement result of the sensor 68 to adjust the clamping force, thereby improving the accuracy of the clamping force.

[0093] Next, the processes of steps S31 and S33 are performed in parallel with step S32. In step S31, timing of the cooling time of the molded product in the mold 100B is started. In step S32, processes related to the mold clamping device 6 are performed. The fixation of the mold 100B by the fixing mechanism 610 is released. After a predetermined time delay from step S30, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space that allows the mold to be replaced.

[0094] In step S33, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0095] More specifically, the pressure-holding suck-back and nozzle shut-off are intended to prevent the molten resin from dripping when the nozzle 52 is separated from the mold 100B. These processes can be performed during the delay time before the movable platen 62 is slightly separated from the fixed platen 61 in step S32. The pressure-holding suck-back is intended to reduce the resin pressure in the injection cylinder 51 and the mold 100B by retracting the screw 51a after pressure-holding. The nozzle shut-off is intended to close the discharge port 52a of the nozzle 52. The above operations make it possible to suppress the leakage of resin. The accuracy of the resin metering for the next injection can be improved. The above processes can prevent the resin from leaking, but depending on the structure of the mold and the type of resin, long strings of resin may occur between the mold 100B and the nozzle 52. These cases can be dealt with by installing a device that blows air into the nozzle 52.

[0096] In step S34, the mold 100B and the mold 100A are replaced with each other. The mold 100B is carried out from the molding operation position 11 to the conveying device 3B, and the mold 100A is carried from the conveying device 3A to the molding operation position 11. The controller 41 transmits an instruction to the controller 42B to carry out the mold 100B, and the controller 42B drives the conveying unit 31 to carry out the mold 100B from the molding operation position 11. When the carrying out of the mold 100B is completed, the controller 42B transmits a signal indicating the carrying out completion to the controller 41. The mold 100B is cooled on the conveying device 3B. The closed state of the mold 100B is maintained by the self-closing portion 103.

[0097] When a signal indicating the completion of loading is received, in step S35, a second set of conditions for the mold 100A is set as the operating conditions for the molding operation. The controller 41 reads out and sets operating condition C from among the multiple operating conditions (operating conditions A, B, and C) set in step S1. The difference between the first set of conditions for the mold 100A and the second set of conditions is the measurement value, injection speed, holding pressure switching position, holding pressure, etc., since the primary molded product and the tertiary molded product must be molded simultaneously in the second set of conditions. Plasticization measurement for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100A. There is no need to generate a clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100A to the fixed platen 61 and the movable platen 62, respectively.

[0098] In this embodiment, step S35 is performed after step S34. In another exemplary embodiment, since it may take time to switch the operating conditions, for example, the operating conditions may be switched simultaneously with the instruction to carry out the mold 100B.

[0099] In step S6666, timing of the cooling time of the molded product in mold 100A begins.

[0100] In step S12222, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time measurement started in step S6666 has reached a predetermined time. If the cooling is completed, the processes of steps S13333 to S15555 and the process of step S14444 are performed in parallel.

[0101] In step S13333, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by the fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610. This allows the movable mold 102 to be separated from the fixed mold 101, and the mold 100A is opened. In step S14444, the ejector 7 is driven to eject the primary molded product remaining on the movable mold 102 side (inside the cavity) of the mold 100A, and transport it to the upper part of the injection molding machine 2, where it waits in a standby state. The vacuum head 74 moves to a position where the chuck plate 75 faces the third primary molded product, and holds the third primary molded product by suction force. The remover 7 continues to hold the third primary molded product from the removal step (S14444) until the insertion (placement) (S26666) of the third primary molded product into the metal mold 100B, which will be described later, is performed.

[0102] 4H-4K show a refinement of the injection molding operation.

[0103] In step S26666, the take-out machine 7 is driven to insert (place) the secondary molded product α (step S14444) that is in a standby state above the injection molding machine 2 onto the movable mold 102 side of the mold 100A.

[0104] In step S10000, the gate G arranged on the fixed side of the mold 100A is driven to open the flow path on the tertiary molded product side. This makes it possible to fill the primary molded product and the tertiary molded product with resin and hold the pressure at the same time with one injection. The gate G can be driven by air, hydraulics, servo, etc.

[0105] In step S15555, the motor 66 is driven to move the movable platen 62 toward the stationary platen 61. This causes the movable mold 102 to come into close contact with the stationary mold 101, and the mold 100A is closed.

[0106] In step S16666, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100A.

[0107] In step S17777, preparations for injection into the mold 100A are made. Here, the actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100A.

[0108] In step S18888, the molten resin is injected and pressure is maintained. The injection in step S18888 is for molding a tertiary molded product x and a primary molded product n.

[0109] More specifically, the injection unit 5 is driven to fill the cavity in the mold 100A with molten resin from the nozzle 52, and the resin is forced into the mold 100A at high pressure to compensate for the volume reduction caused by the solidification of the resin. During the processing of step S18888, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand. There may be a difference between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, the initial value of the position of the movable platen 63 relative to the tie bar 64 is corrected according to the measurement result of the sensor 68 to adjust the clamping force, thereby improving the accuracy of the clamping force.

[0110] Next, the processes of steps S19999 and S21000 are performed in parallel with step S20000. In step S19999, timing of the cooling time of the molded product in the mold 100A is started. In step S20000, processes related to the mold clamping device 6 are performed. The fixation of the mold 100A by the fixing mechanism 610 is released. After a predetermined time delay from step S18888, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space that allows the mold to be replaced.

[0111] In step S21000, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0112] The pressure holding suck back and nozzle shut off are to prevent the molten resin from dripping when the nozzle 52 is separated from the mold 100A. These processes can be performed during the delay time before the movable platen 62 is slightly separated from the fixed platen 61 in step S20000. The pressure holding suck back is to reduce the resin pressure in the injection cylinder 51 and the mold 100A by retracting the screw 51a after pressure holding. The nozzle shut off is to close the discharge port 52a of the nozzle 52. This operation makes it possible to suppress the leakage of resin and improve the accuracy of the resin measurement for the next injection. The above processes can prevent the resin from leaking. Depending on the structure of the mold and the type of resin, long strings of resin may be generated between the mold 100A and the nozzle 52. To prevent this, a device for blowing air to the nozzle 52 may be installed.

[0113] Through the above steps of injection preparation (S17777), injection pressure hold (S18888), and cooling (timing start and completion determination), the tertiary molded product x and primary molded product n are molded. The cooling process of the injected resin is carried out from the start of cooling time measurement in step S19999 to the completion determination in step S36, and is a process of cooling the molten resin in the mold by a temperature regulator (not shown) connected to the mold 100A or air supplied from outside the injection molding system 1.

[0114] At least a part of the cooling process of the mold 100A is performed on the transfer device 3A, not at the molding operation position 11. The cooling process of the mold 100A is performed in parallel with at least a part of the process from the replacement of the mold in S22222 to the replacement of the mold in S344, for example, removal of the secondary molded product α from the mold 100B at the molding operation position 11 (S144444) and arrangement of the primary molded product (S266666), which will be described later.

[0115] In step S22222, the mold 100A and the mold 100B are replaced. The mold 100A is carried out from the molding operation position 11 to the conveying device 3A, and the mold 100B is carried from the conveying device 3B to the molding operation position 11. The controller 41 transmits an instruction to the controller 42A to carry out the mold 100A, and the controller 42A drives the conveying unit 31 to carry out the mold 100A from the molding operation position 11. When the carrying out of the mold 100A is completed, the controller 42A transmits a signal indicating the carrying out completion to the controller 41. The mold 100A is cooled on the conveying device 3A. The closed state of the mold 100A is maintained by the self-closing portion 103.

[0116] When a signal indicating the completion of loading is received, in step S23333, the conditions related to the mold 100B are set as the operating conditions for the molding operation. That is, the controller 41 reads out and sets the operating condition B from among the multiple operating conditions (operating conditions A, B, and C) set in step S1. For example, the thickness (width in the Y direction) of the mold 100B, the mold clamping force, etc. are set as the operating conditions for the current molding operation. In addition, operating conditions such as the injection speed corresponding to the mold 100B are also set. Plasticization metering for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100B. At this time, it is not necessary to generate the mold clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100B to the fixed platen 61 and the movable platen 62, respectively.

[0117] In this embodiment, step S23333 is performed after step S22222. In another exemplary embodiment, since it may take time to switch the operating conditions, for example, the operating conditions may be switched simultaneously with the instruction to unload the mold 100A.

[0118] In step S66666, timing of the cooling time of the molded product in the mold 100B begins.

[0119] In step S122222, it is determined whether cooling of the mold 100B is complete based on whether the cooling time measurement of which began in step S66666 has reached a predetermined time. When cooling is complete, the processes of steps S133333 to S155555 and the process of step S144444 are performed in parallel.

[0120] The secondary molded product y is molded through the above steps of injection preparation (S17777), injection pressure hold (S18888), and cooling (timing start and completion determination) (S66666, S122222). The cooling process of the injected resin is performed from the start of cooling time measurement in step S66666 to the completion determination in step S122222, and is a process of cooling the molten resin in the mold by a temperature regulator (not shown) connected to the mold 100A or air supplied from outside the injection molding system 1.

[0121] In step S133333, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by the fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610. This allows the movable mold 102 to be separated from the fixed mold 101, and the mold 100B is opened. In step S144444, the ejector 7 is driven to eject the secondary molded product α remaining on the movable mold 102 side (inside the cavity) of the mold 100B, transport it to the upper part of the injection molding machine 2, and maintain a standby state there. The vacuum head 74 moves to a position where the chuck plate 75 faces the secondary molded product α, and holds the secondary molded product α by suction force. The remover 7 continues to hold the secondary molded product α from the removal step (S144444) until the insertion (placement) of the secondary molded product α into the metal mold 100B (S26666) is performed.

[0122] In step S155555, the motor 66 is driven to move the movable platen 62 toward the stationary platen 61. This causes the movable mold 102 to come into close contact with the stationary mold 101, and the mold 100B is closed.

[0123] In step S166666, motor 66 is driven to drive toggle mechanism 65, and mold 100B is clamped by fixed platen 61 and movable platen 62. In step S177777, preparations for injection into mold 100B are made. Here, actuator 55 is driven to move injection unit 5, and nozzle 52 is brought into contact with mold 100B.

[0124] In step S188888, molten resin is injected and pressure is maintained. The injection in step S188888 is for molding a secondary molded product y having the same shape as in step S177.

[0125] More specifically, the injection unit 5 is driven to fill the cavity in the mold 100B with molten resin from the nozzle 52, and the resin is pushed in at high pressure to compensate for the volume reduction caused by the solidification of the resin. During the processing of step S188888, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100B gradually increases, causing the mold 100B to thermally expand, and a difference may occur between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, the initial value of the position of the movable platen 63 relative to the tie bar 64 is corrected according to the measurement result of the sensor 68 to adjust the clamping force, thereby improving the accuracy of the clamping force.

[0126] Next, the processes of steps S311 and S333 are performed in parallel with step S322. In step S311, timing of the cooling time of the molded product in the mold 100B is started. In step S322, processes related to the mold clamping unit 6 are performed. The fixation of the mold 100B by the fixing mechanism 610 is released. After a predetermined time delay from step S188888, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space that allows the mold to be replaced.

[0127] In step S333, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0128] The pressure holding suck back and nozzle shut off are to prevent the molten resin from dripping when the nozzle 52 is separated from the mold 100B. These processes can be performed during the delay time before the movable platen 62 is slightly separated from the fixed platen 61 in step S322. The pressure holding suck back is to reduce the resin pressure in the injection cylinder 51 and the mold 100B by retracting the screw 51a after pressure holding. The nozzle shut off is to close the discharge port 52a of the nozzle 52. This operation makes it possible to suppress the leakage of resin and improve the accuracy of the resin measurement for the next injection. The above processes can prevent the resin from leaking. Depending on the structure of the mold and the type of resin, long strings of resin may be generated between the mold 100B and the nozzle 52. To prevent this, a device for blowing air to the nozzle 52 may be installed.

[0129] In step S344, the mold 100B is replaced with the mold 100A. The mold 100B is carried out from the molding operation position 11 to the conveying device 3B, and the mold 100A is carried from the conveying device 3A to the molding operation position 11. The controller 41 transmits an instruction to the controller 42B to carry out the mold 100B, and the controller 42B drives the conveying unit 31 to carry out the mold 100B from the molding operation position 11. When the carrying out of the mold 100B is completed, the controller 42B transmits a signal indicating the carrying out completion to the controller 41. The mold 100B is cooled on the conveying device 3B. The closed state of the mold 100B is maintained by the self-closing portion 103.

[0130] When a signal indicating the completion of loading is received, in step S355, a second set of conditions for the mold 100A is set as the operating conditions for the molding operation. The controller 41 reads out and sets operating condition C from among the multiple operating conditions (operating conditions A, B, and C) set in step S1. The difference between the first set of conditions for the mold 100A and the second set of conditions is the measurement value, injection speed, holding pressure switching position, holding pressure, etc., since the primary molded product and the tertiary molded product need to be molded simultaneously in the second set of conditions. Plasticization measurement for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100A. At this time, it is not necessary to generate a clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100A to the fixed platen 61 and the movable platen 62, respectively.

[0131] In this embodiment, step S355 is performed after step S344. In another exemplary embodiment, since it may take time to switch the operating conditions, for example, the operating conditions may be switched simultaneously with the instruction to unload the mold 100B.

[0132] In step S36, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time that began to be measured in step S19999 has reached a predetermined time. If the cooling is completed, the processes from step S37 to step S39 and the process of step S38 are performed in parallel.

[0133] In step S37, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. As a result, the movable mold 102 is separated from the fixed mold 101, and the mold 100A is opened. In step S38, the ejector 7 is driven to eject the molded product remaining on the movable mold 102 side of the mold 100A and transport it to the outside of the injection molding system 1. The vacuum head 74 moves to a position where the chuck plate 75 faces the tertiary molded product x and the primary molded product n, and holds them by suction. The removed finished product is separated from the tertiary molded product x and the primary molded product n held by suction. The tertiary molded product x is placed on a belt conveyor (not shown) or directly carried into a storage location, for example, a box (not shown), by the ejector 7.

[0134] In step S39, the number of molded products produced at this time point is compared with the expected production quantity TH. The number of molded products produced so far is stored in a ROM or RAM (not shown). The production quantity TH is the target production quantity set in step S1.

[0135] If the number of molded products is less than the expected production quantity TH, the process returns to step S26666, and the above process is repeated. In other words, the process proceeds to inserting / injecting / pressure-holding the primary molded products into the mold 100A and the mold 100B, and replacing the mold 100A with the mold 100B.

[0136] When the number of molded parts reaches the expected production quantity TH, the process ends.

[0137] With the holding part 74A of the extractor 7 holding the primary molded product n and the holding part 74B holding the secondary molded product y, the tertiary molded product x is extracted by the holding part 74C.

[0138] Next, an example of an exemplary embodiment of the above process is shown, in which the tertiary molded products x1, x2, x3, and x4 are completed in this order. As described above, before the first tertiary molded product (e.g., x1) is completed, not only is the molding process of the primary molded product n2 and the secondary molded product y2 for the second tertiary molded product (e.g., x2) that should be completed after the completion of the first tertiary molded product x1 started, but the primary molded product n2 and the secondary molded product y2 for x2 are also already completed. The primary molded product n3 and the secondary molded product y3 for x3 are also injected. When considering the transition from step S39 to step S26666, in step S26666, the secondary molded product y2 for x2 is taken out in step S144444 after step S26666. In other words, the secondary molded product for x2 is completed before x1 is taken out. <Forming behavior>

[0139] 5A to 5R show a molding process using a mold configuration for primary to tertiary molded products by an injection molding system implementing the processes of FIGS. 4A to 4K.

[0140] In this exemplary embodiment, based on the order in which the primary molded parts were created, the primary molded parts are referred to as primary molded part 1, primary molded part 2, primary molded part 3, etc. When it is not necessary to specify which primary molded part is being referred to, primary molded part n will be used.

[0141] In this exemplary embodiment, the secondary molded product is a molded product generated by performing an injection process on the primary molded product n. Based on the order of generation, the secondary molded products are called secondary molded products α and β. When it is not necessary to specify which secondary molded product to refer to, the secondary molded product y is used.

[0142] In this exemplary embodiment, the tertiary molded product is a molded product generated by additionally performing an injection process on the secondary molded product y. The tertiary molded product is referred to as a tertiary molded product x.

[0143] 5A to 5R are cross-sectional views of the molds 100A and 100B and the cavity shape on the movable mold 102 side.

[0144] 5A shows a cross section of mold 100A parallel to the YZ plane and a plan view of movable mold 102 in the negative Y-axis direction. When mold 100A is located inside injection molding machine 2, the mold opening direction is the positive Y-axis direction, the ejection direction of mold 100A to the transport device 3A side is the negative X-axis direction, and the vertical direction is the positive Z-axis direction.

[0145] The mold 100A is a mold for molding a primary molded product 1(n) and a tertiary molded product x, which will be described later, and includes a movable mold 102, a cavity 104n corresponding to the primary molded product 1, and a cavity 104x corresponding to the tertiary molded product 3. The cavities 104n and 104x of the mold 100A each have a convex shape in the XZ plane. The cavity of the movable mold 102 also has a planar shape, and has an arbitrary lens shape in the cavities 104n and 104x. The cavity 104x can receive a secondary molded product α(y), which will be described later, and after the mold is closed, the secondary molded product α(y) can be overmolded to form the tertiary molded product x.

[0146] The mold 100B is a mold for molding a secondary molded product α(x) and is composed of a cavity 104x corresponding to the secondary molded product α. The fixed cavity 104y of the mold 100B has a convex shape in the XZ plane. The cavity of the movable mold 102 has a planar shape and has an arbitrary lens shape in the cavity 104y.

[0147] The cavity 104y can receive the primary molded product 1(n), and after the mold is closed, the primary molded product 1(n) can be overmolded to form a secondary molded product α(y).

[0148] Fig. 5A shows the mold 100A in a closed state, and the mold configuration in steps S1 to S4 in Fig. 4A. The fixed mold 101 has a protruding portion 131 corresponding to the curved surface 105 of the primary molded product 1(n) and a protruding portion 106 corresponding to the curved surface 132 of the tertiary molded product x. The curved surfaces 105 and 106 may be any lens shape.

[0149] On the other hand, the movable mold 102 has a planar shape.

[0150] Fig. 5B shows a state in which molten resin has been poured into a cavity 104n of a metal mold 100A for producing a primary molded product 1(n), and shows the configuration of the metal mold in steps S5 to S12 of Fig. 4A. The primary molded product 1 is formed within the metal mold 100A.

[0151] 5C shows a state where the mold 100A is opened and the lifting shaft 73A of the ejector 7 has entered the mold 100A, and shows a series of operations in step S14 in FIG. 4B. The primary molded product 1(n) is held by a holding part (chuck) 74A connected to the lifting shaft 73A of the ejector 7 and is removed from the movable mold 102. The holding part 74A holds a part of the gate part of the primary molded product 1(n) by using an adsorption force. As described later, before arranging (inserting) the gate in the mold 100B, the gate is provisionally arranged in a dedicated position, and the holding direction of the gate by the holding part 74A is changed. The holding part 74A may be of a type other than a vacuum type.

[0152] In addition to the vertical movement as described above, the extractor 7 of this embodiment has a rotation mechanism 78 that can rotate at least the holding part 74A in the axial direction at least 180 degrees by rotating the lifting shaft 73A about its axis. The rotation mechanism 78 can also be provided with a mechanism for moving the lifting shaft 73A or the holding part 74A up and down (z-axis direction), or a mechanism for moving the lifting shaft 73A or the holding part 74A left and right (y-axis direction, mold clamping / mold opening direction).

[0153] As described below, the rotation mechanism is used to position the primary molded product 1 removed from the movable mold 102 on the movable mold 102, and considering this purpose, it is sufficient if it can rotate at least the holding portion 74A 180 degrees around an axis in a direction parallel to the surfaces (XZ plane) of the platens 61 and 62 of the injection molding machine 2.

[0154] The rotation mechanism 78 and the vertical / horizontal movement mechanism are controlled by a control unit of the take-out machine 7 , and the control unit is controlled by the controller 41 of the injection molding system 1 .

[0155] Fig. 5D shows a state in which molten resin has been poured into cavity 104n of mold 100A for manufacturing primary molded product 2(n), and is one embodiment of the mold in steps S15 to S122 of Fig. 4B. Primary molded product 2(n) is formed in mold 100A. At this time, primary molded product 1 described in step S14 is held by holding portion 74A and is in a standby state above injection molding machine 2.

[0156] Fig. 5E shows a state in which the mold 100A is opened and the lift shaft 73B of the extractor 7 is disposed in the mold 100A, and shows a series of operations associated with step S144 in Fig. 4C. The primary molded product 2(n) is held by a holding part (chuck) 74B connected to the lift shaft 73B of the extractor 7 and is removed from the movable mold 102.

[0157] 5F shows a state in which molten resin has been poured into cavity 104n of mold 100A for producing primary molded product 3(n), and is one embodiment of the mold in steps S155 to S177 of FIG. 4E. Primary molded product 3 is formed in mold 100A. At this time, primary molded products 1 and 2 are held by holders 74A and 74B, and stored in the upper part of injection molding machine 2.

[0158] Fig. 5G shows the mold 100B in an open state, and the state (inserted state) in which the holding part 74A that holds the primary molded product 1 has entered the mold 100B. This state shows a series of operations in step S26 in Fig. 4D.

[0159] The flat surface portion 116 of the primary molded product 1 is inserted into the insert holder 117 of the movable mold 102 , and the primary molded product 1 is positioned and placed within the recess (cavity) of the movable mold 102 .

[0160] The movable mold 102 forms a part of the cavity 110 of the secondary molded product, and a recess 110B in which the primary molded product 1 is placed (inserted) fits into a protrusion 115 of the primary molded product 1. The fixed mold 101 forms a part of the cavity 110, and is configured in a flat shape.

[0161] Fig. 5H shows a state in which the secondary molded product α is overmolded in the movable mold 102 of the mold 100B, and the secondary molded product α(y) is formed by injecting (overmolding) resin with the primary molded product 1 inserted. This state shows a series of operations in steps S27 to S1222 in Fig. 4D.

[0162] 5I shows a state in which the mold 100B is opened and the lifting shaft 73C of the extractor 7 is inserted into the mold 100B, and a series of operations in step S1444 in FIG. 4E will be described. The secondary molded product α(y) is held by suction force by a holding part (chuck) 74C connected to the lifting shaft 73C of the extractor 7, and is removed from the movable mold 102.

[0163] Fig. 5J shows the mold 100B in an open state, and a state (inserted state) in which the holding part 74B that holds the primary molded product 2 is inserted into the mold 100B. A series of operations in step S266 in Fig. 4E is shown.

[0164] The flat surface portion 116 of the primary molded product 2 is inserted into the insert holder 117 of the movable mold 102 , and the primary molded product 2 is positioned and placed within the recess (cavity) of the movable mold 102 .

[0165] The movable mold 102 forms a part of the cavity 110 of the secondary molded product, and a recess 110B in which the primary molded product 2 is placed (inserted) fits into a protrusion 115 of the primary molded product 2. The fixed mold 101 forms a part of the cavity 110, and is configured in a flat shape.

[0166] Fig. 5K shows a case where a secondary molded product β(y) is overmolded in the movable mold 102 of the mold 100B, and the secondary molded product β(y) is formed by injecting (overmolding) resin with the primary molded product 2(n) inserted. A series of operations in steps S155 to S1888 in Fig. 4E will be described.

[0167] Fig. 5L shows a state in which the mold 100A is opened and the lifting shaft 73A of the ejector 7 is inserted into the mold 100A. The primary molded product 3(n) is held by suction force by a holding part (chuck) 74A connected to the lifting shaft 73A of the ejector 7. A series of operations in step S14444 in Fig. 4G are shown.

[0168] Fig. 5M shows a state in which the metal mold 100A is opened and the secondary molded product α(y) is inserted into the holding portion 74C of the metal mold 100A (inserted state). A series of operations in step S26666 in Fig. 4K will be described.

[0169] By vacuum adsorption from the movable mold 102 side, the secondary molded product α(y) is positioned and arranged in the recessed portion (cavity) of the movable mold 102 of the primary molded product 3 .

[0170] The gate 200 can be switched 180 degrees to enable overmolding onto the secondary molded product α(y). This allows the primary molded product and the tertiary molded product to be molded simultaneously. The switching can be done by air, hydraulics, servo, etc.

[0171] Fig. 5N shows a state where the tertiary molded product x is overmolded in the movable mold 102 of the mold 100A, and resin is injected (overmolded) with the secondary molded product α(y) inserted to form the tertiary molded product x. One of the cavities is filled with the primary molded product n. A series of operations in steps S15555 to S18888 in Fig. 4K is shown.

[0172] One result of this exemplary embodiment is that thick lenses can be efficiently manufactured using two insert molding operations.

[0173] 5O shows a state in which the mold 100B is opened and the lifting shaft 73C of the extractor 7 is inserted into the mold 100B, and shows a series of operations in step S144444 in FIG. 4I. The secondary molded product β(y) is held by suction force by a holding part (chuck) 74C connected to the lifting shaft 73C of the extractor 7, and is removed from the movable mold 102.

[0174] Fig. 5P shows a state (inserted state) in which the metal mold 100B is opened and the holding part 74A that holds the primary molded product 3 is inserted into the metal mold 100B. A series of operations in step S26666 in Fig. 4I is shown.

[0175] Fig. 5Q shows a state in which the secondary molded product y is overmolded in the movable mold 102 of the mold 100B, and the secondary molded product y is formed by injecting (overmolding) resin with the primary molded product n inserted. A series of operations in steps S155555 to S188888 in Fig. 4I and Fig. 4K are shown.

[0176] FIG. 5R shows the open state of the mold 100A from which the tertiary molded product x and the primary molded product n have been removed. The tertiary molded product x is held by the holding part 74B with suction force, and the primary molded product n is held by the holding part 74A with suction force. The tertiary molded product x and the primary molded product n are simultaneously transported to the outside of the mold 100A and separated into the tertiary molded product and the primary molded product by a cutting mechanism (not shown) having a gate cutting function. The tertiary molded product is transported to the outside of the injection molding machine 2 and loaded onto a belt conveyor (not shown) or the like. This completes a thick-walled molded product. The primary molded product n, held by the holding part 74C with suction force, is held at the top of the injection molding machine 2 until it is inserted into the mold 100B.

[0177] Using the conveying devices 3A and 3B, the molds 100A and 100B can be loaded and unloaded into and from the injection molding machine 2 while a plurality of thick lens molded products x are manufactured in parallel, thereby shortening the waiting time of the injection molding machine 2 and achieving efficient manufacturing.

[0178] In another exemplary embodiment using an injection molding system including the conveying device 3A and the conveying device 3B, it is not necessary to perform a process of making the primary molded products α1 and α2 wait while being held by the holding parts 74A and 74B of the take-out machine 7 above the injection molding machine 2. The primary molded products α1 and α2 are taken out by the take-out machine 7 and temporarily placed in a storage location for storing primary molded products provided outside the injection molding machine 2, such as a box.

[0179] In an exemplary embodiment, the mold 100A and the mold 100B can be connected to each other, for example, via a connector. In another exemplary embodiment, the mold 100A and the mold 100B can be an integrated unit. For example, the fixed mold 101 of the mold 100A and the fixed mold 101 of the mold 100B can be integrated.

[0180] Although an example of two overmolding operations is shown, one or more overmolding operations may be performed. <Production of molded products>

[0181] 6A to 6I show an example of the operation of the injection molding system 1. In the following example, a molding operation is performed by interchanging the mold 100A and the mold 100B.

[0182] 6A to 6F show a flowchart illustrating the molding process. In step S1, initial settings are performed. The operating conditions of the injection unit 5 and the clamping unit 6 are registered for each of the mold 100A and the mold 100B. For example, these include the amount of resin injected per injection, temperature, injection speed, clamping force, and initial values ​​of the position of the movable platen 63 relative to the tie bars 64. These conditions may be the same or different between the mold 100A and the mold 100B.

[0183] The first molding operation uses the mold 100A, and conditions related to the mold 100A are automatically set as the first operating conditions. Initial heating of the injection cylinder 51, plasticization and metering of the resin, etc. are started. As will be described later, even in the case of the operating conditions of the mold 100A, the operating conditions for molding the primary molded product n may differ from the operating conditions for molding the primary molded product n and the tertiary molded product x.

[0184] In step S1, the controller 41 sets operating conditions A for forming a primary molded product n using the mold 100A, operating conditions B for forming a secondary molded product y using the mold 100B, and operating conditions C for forming the primary molded product n and the tertiary molded product x using the mold 100A.

[0185] In step S2, the mold 100A is transported into the injection molding machine 2. The motor 66 is driven to make the gap between the fixed platen 61 and the movable platen 62 slightly wider than the thickness (width in the Y direction) of the mold 100A. Next, the controller 41 transmits an instruction to the controller 42A to carry in the mold 100A, and the controller 42A drives the transport unit 31 to carry in the mold 100A to the molding operation position 11. When the carry-in is completed, a signal indicating the carry-in completion is transmitted from the controller 42A to the controller 41. When the signal indicating the carry-in completion is received, the motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100A. At this time, it is not necessary to generate a clamping force that is generated during molding. In addition, the fixing mechanism 610 is driven to fix the mold 100A to the fixed platen 61 and the movable platen 62, respectively.

[0186] In step S3, motor 66 is driven to drive toggle mechanism 65, and mold 100A is clamped by fixed platen 61 and movable platen 62. In step S4, preparation for injection into mold 100A is performed. Here, actuator 55 is driven to move injection unit 5, and nozzle 52 is brought into contact with mold 100A.

[0187] In step S5, the molten resin is injected and pressure is maintained. More specifically, the injection device 5 is driven to fill the cavity in the mold 100A with the molten resin from the nozzle 52, and the resin is pushed in at high pressure to compensate for the volume reduction caused by the solidification of the resin. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand. There may be a difference between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, the initial value of the position of the movable platen 63 relative to the tie bar 64 is corrected according to the measurement result of the sensor 68 to adjust the clamping force, thereby improving the accuracy of the clamping force.

[0188] In step S6, timing of the cooling time of the molded product in the mold 100A is started. In step S7, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time measurement started in step S6 has reached a predetermined time.

[0189] The first primary molded product is molded through the above-mentioned steps of injection preparation (S4), injection pressure hold (S5), and cooling (time measurement start and completion determination). The cooling process of the injected resin is carried out from the start of cooling time measurement in step S6 to the completion determination in step S7, and is a process of cooling the molten resin in the mold 100A by a temperature regulator (not shown) connected to the mold 100A or by air supplied from outside the injection molding system 1.

[0190] In step S8, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. This causes the movable mold 102 to be separated from the fixed mold 101, and the mold 100A is opened. In step S9, the ejector 7 is driven to eject the primary molded product remaining on the movable mold 102 side (inside the cavity) of the mold 100A, and transports it to the upper part of the injection molding machine 2 to maintain a standby state. The ejector 7 continues to hold the first primary molded product from the ejection process (S9) until the first primary molded product is inserted (placed) into the mold 100B (S20), which will be described later.

[0191] In step S10, the motor 66 is driven to move the movable platen 62 toward the fixed platen 61. This brings the movable mold 102 into close contact with the fixed mold 101, and the mold 100A is closed.

[0192] In step S11, the motor 66 is driven to drive the toggle mechanism 65, and the mold 100A is clamped by the fixed platen 61 and the movable platen 62. In step S12, preparations for injection into the mold 100A are made. Here, the actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100A.

[0193] In step S13, the molten resin is injected and pressure is maintained. The injection in step S13 is for molding a second primary molded product having the same shape as in step S5.

[0194] More specifically, the injection unit 5 is driven to fill the cavity in the mold 100A with molten resin from the nozzle 52, and the resin is pushed in at high pressure to compensate for the volume reduction caused by the solidification of the resin. During the process of step S13, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand. There may be a difference between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, the initial value of the position of the movable platen 63 relative to the tie bar 64 is corrected according to the measurement result of the sensor 68 to adjust the clamping force, thereby improving the accuracy of the clamping force. The position adjustment of the movable platen 63 relative to the tie bar 64 may be performed at any timing.

[0195] Next, the processes of steps S14 and S16 are performed in parallel with the process of step S15. In step S14, timing of the cooling time of the molded product in the mold 100A is started. In step S15, processes related to the mold clamping device 6 are performed. The fixation of the mold 100A by the fixing mechanism 610 is released. After a predetermined time delay from step S13, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space in which the mold 100A and the mold 100B can be interchanged.

[0196] In step S16, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0197] The pressure holding suck back and nozzle shut off are to prevent the molten resin from dripping when the nozzle 52 is separated from the mold 100A. These processes can be performed during the delay time before the movable platen 62 is slightly separated from the fixed platen 61 in step S15. The pressure holding suck back is to reduce the resin pressure in the injection cylinder 51 and the mold 100A by retracting the screw 51a after pressure holding. The nozzle shut off is to close the discharge port 52a of the nozzle 52. This operation makes it possible to suppress the leakage of resin and improve the accuracy of the resin measurement for the next injection. The above processes can prevent the resin from leaking. Depending on the structure of the mold and the type of resin, long strings of resin may be generated between the mold 100A and the nozzle 52. To prevent this, a device for blowing air to the nozzle 52 may be installed.

[0198] In step S17, the mold 100A and the mold 100B are replaced. The mold 100A is carried out from the molding operation position 11 to the conveying device 3A, and the mold 100B is carried from the conveying device 3B to the molding operation position 11. The controller 41 transmits an instruction to the controller 42A to carry out the mold 100A, and the controller 42A drives the conveying unit 31 to carry out the mold 100A from the molding operation position 11. The mold 100B moves from the conveying device 3B to the molding operation position 11. When the carrying out of the mold 100A is completed, the controller 42A transmits a signal indicating the carrying out completion to the controller 41. The mold 100A is cooled on the conveying device 3A. The closed state of the mold 100A is maintained by the self-closing portion 103.

[0199] When a signal indicating the completion of loading is received, in step S18, the conditions related to the mold 100B are set as the operating conditions for the molding operation. That is, the controller 41 reads out and sets the operating condition B from among the multiple operating conditions (operating conditions A, B, and C) set in S1. For example, the thickness (width in the Y direction) of the mold 100B, the mold clamping force, etc. are set as the operating conditions for the current molding operation. Operating conditions such as the injection speed corresponding to the mold 100B are set. Plasticization metering for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100B. At this time, it is not necessary to generate the mold clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100B to the fixed platen 61 and the movable platen 62, respectively.

[0200] In the above embodiment, step S18 is performed after step S17. In another exemplary embodiment, since it may take time to switch the operating conditions, for example, the operating conditions may be switched simultaneously with the instruction to unload the mold 100A.

[0201] In step S19, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. This causes the movable mold 102 to be separated from the fixed mold 101, and the mold 100B is opened. In step S20, the ejector 7 is driven to insert (place) the first primary molded product that was placed in a standby state in step S9 into the mold 100B.

[0202] In step S21, the motor 66 is driven to move the movable platen 62 toward the fixed platen 61. This brings the movable mold 102 into close contact with the fixed mold 101, and the mold 100B is closed.

[0203] In step S22, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100B. In step S23, preparations for injection into the mold 100B are made. The actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100B. The secondary molded product α is molded with the first primary molded product placed in the mold 100B, and in step S24, resin is injected into the primary molded product to be integrated with it to perform overmolding.

[0204] Next, the processes of steps S25 and S27 are performed in parallel with the process of step S26. In step S25, timing of the cooling time of the molded product in the mold 100B is started. In step S26, processes related to the mold clamping device 6 are performed. The fixation of the mold 100B by the fixing mechanism 610 is released. After a predetermined time delay from step S24, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space for replacing the mold 100B with the mold 100A.

[0205] In step S27, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0206] In step S28, the mold 100B is replaced with the mold 100A. The mold 100B is carried out from the molding operation position 11 to the conveying device 3B, and the mold 100A is carried in from the conveying device 3A to the molding operation position 11. The controller 41 transmits a carry-out instruction for the mold 100B to the controller 42B, and the controller 42B drives the conveying unit 31 to carry out the mold 100B from the molding operation position 11. The mold 100A moves from the conveying device 3A to the molding operation position 11. When the carry-out of the mold 100B is completed, a signal indicating the completion of the carry-out is transmitted from the controller 42B to the controller 41. The mold 100B is cooled on the conveying device 3B. At this time, the closed state of the mold 100B is maintained by the self-closing portion 103.

[0207] When a signal indicating the completion of loading is received, in step S29, the conditions related to the mold 100A are set as the operating conditions for the molding operation. That is, the controller 41 reads out and sets the corresponding operating conditions from among the multiple operating conditions (operating conditions A, B, and C) set in S1. For example, the thickness (width in the Y direction) of the mold 100A, the mold clamping force, etc. are set as the operating conditions for the current molding operation. Operating conditions such as the injection speed corresponding to the mold 100A are set. Plasticization metering for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100A. At this time, it is not necessary to generate the mold clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100A to the fixed platen 61 and the movable platen 62, respectively.

[0208] In step S30, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time, the measurement of which was started in step S14, has reached a predetermined time.

[0209] In step S31, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. As a result, the movable mold 102 is separated from the fixed mold 101, and the mold 100A is opened.

[0210] In step S32, the ejector 7 is driven to eject the second primary molded product remaining on the movable mold 102 side (inside the cavity) of the mold 100A, and transports it to an upper region of the injection molding machine 2 and places it in a standby state. The ejector 7 continues to hold the second primary molded product from the ejection step (S32) until the second primary molded product is inserted (placed) (S45) into the mold 100B, which will be described later.

[0211] In step S33, the motor 66 is driven to move the movable platen 62 toward the fixed platen 61. This brings the movable mold 102 into close contact with the fixed mold 101, and the mold 100A is closed.

[0212] In step S34, motor 66 is driven to drive toggle mechanism 65, and mold 100A is clamped by fixed platen 61 and movable platen 62. In step S35, preparations for injection into mold 100A are made. Here, actuator 55 is driven to move injection unit 5, and nozzle 52 is brought into contact with mold 100A.

[0213] In step S36, the molten resin is injected and pressure-held. The injection in step S36 is for molding a third primary molded product having the same shape as in step S5. More specifically, the injection device 5 is driven to fill the cavity in the mold 100A with the molten resin from the nozzle 52, and the resin is pushed in at high pressure to compensate for the volume reduction caused by the solidification of the resin. In the process of step S36, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand. There may be a difference between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, the accuracy of the mold clamping force can be improved by adjusting the mold clamping force by correcting the initial value of the position of the movable platen 63 relative to the tie bars 64 in accordance with the measurement results of the sensor 68. The position adjustment of the movable platen 63 relative to the tie bars 64 may be performed at any desired timing.

[0214] Next, the processes of steps S37 and S39 are performed in parallel with the process of step S38. In step S37, timing of the cooling time of the molded product in the mold 100A is started. In step S38, processes related to the mold clamping unit 6 are performed. The fixation of the mold 100A by the fixing mechanism 610 is released. After a predetermined time delay from step S36, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space in which the mold 100A and the mold 100B can be interchanged.

[0215] In step S39, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0216] In step S40, the mold 100A is replaced with the mold 100B. The mold 100A is carried out from the molding operation position 11 to the conveying device 3A, and the mold 100B is carried from the conveying device 3B to the molding operation position 11. The controller 41 transmits an instruction to the controller 42A to carry out the mold 100A, and the controller 42A drives the conveying unit 31 to carry out the mold 100A from the molding operation position 11. The mold 100B moves from the conveying device 3B to the molding operation position 11. When the carrying out of the mold 100A is completed, the controller 42A transmits a signal indicating the carrying out completion to the controller 41. The mold 100A is cooled on the conveying device 3A. The closed state of the mold 100A is maintained by the self-closing portion 103.

[0217] When a signal indicating the completion of loading is received, in step S40, the conditions related to the mold 100B are set as the operating conditions for the molding operation. That is, the controller 41 reads out and sets the corresponding operating conditions from among the multiple operating conditions (operating conditions A, B, and C) set in S1. For example, the thickness (width in the Y direction) of the mold 100B, the mold clamping force, etc. are set as the operating conditions for the current molding operation. Operating conditions such as the injection speed corresponding to the mold 100B are set. Plasticization metering for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100B. At this time, it is not necessary to generate the mold clamping force that is generated during molding. In addition, the fixing mechanism 610 is driven to lock the mold 100B to the fixed platen 61 and the movable platen 62, respectively.

[0218] In this exemplary embodiment, step S41 is performed after step S40. In another exemplary embodiment, since it may take time to switch the operating conditions, for example, the operating conditions may be switched simultaneously with an instruction to unload the mold 100A.

[0219] In step S42, it is determined whether the cooling of the mold 100B is completed based on whether the cooling time, the measurement of which was started in step S25, has reached a predetermined time.

[0220] In step S43, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by the fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610. As a result, the movable mold 102 is separated from the fixed mold 101, and the mold 100B is opened. In step S44, the ejector 7 is driven to eject the secondary molded product α remaining on the movable mold 102 side (inside the cavity) of the mold 100B, and after inserting a second primary molded product on the movable mold 102 side of the mold 100B, it is transported to the upper part of the injection molding machine 2 and made to wait. The ejector 7 continues to hold the secondary molded product α from the ejection process (S44) until the insertion (placement) (S58) of the secondary molded product α into the mold 100A described later is performed.

[0221] In step S46, the motor 66 is driven to move the movable platen 62 toward the fixed platen 61. This causes the movable mold 102 to come into close contact with the fixed mold 101, and the mold 100B is closed.

[0222] In step S47, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100B. In step S48, preparations for injection into the mold 100B are made. The actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100B. The secondary molded product β is molded with the second primary molded product placed in the mold 100B, and in step S49, resin is injected into the second primary molded product to be integrated with it to perform overmolding.

[0223] Next, the processes of steps S50 and S52 are performed in parallel with the process of step S51. In step S50, timing of the cooling time of the molded product in the mold 100B is started. In step S51, processes related to the mold clamping device 6 are performed. The fixation of the mold 100B by the fixing mechanism 610 is released. After a predetermined time delay from step S49, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space for replacing the mold 100B with the mold 100A.

[0224] In step S52, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0225] In step S53, the mold 100B and the mold 100A are replaced. The mold 100B is carried out from the molding operation position 11 to the conveying device 3B, and the mold 100A is carried in from the conveying device 3A to the molding operation position 11. The controller 41 transmits an instruction to the controller 42B to carry out the mold 100B, and the controller 42B drives the conveying unit 31 to carry out the mold 100B from the molding operation position 11. The mold 100A moves from the conveying device 3A to the molding operation position 11. When the carrying out of the mold 100B is completed, the controller 42B transmits a signal indicating the carrying out completion to the controller 41. The mold 100B is cooled on the conveying device 3B. The closed state of the mold 100B is maintained by the self-closing portion 103.

[0226] When a signal indicating completion of loading is received, in step S54, conditions related to the mold 100A are set as operating conditions for the molding operation. In order to move from this process to a process of simultaneously molding a primary molded product and a tertiary molded product, operating conditions C for the mold 100A are set, and these operating conditions C are different from operating conditions A. Conditions such as mold clamping force and measurement values ​​may differ between operating conditions A and C.

[0227] Plasticization metering for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100A. At this time, it is not necessary to generate the mold clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100A to the fixed platen 61 and the movable platen 62, respectively.

[0228] In step S55, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time, the measurement of which was started in step S36, has reached a predetermined time.

[0229] In step S56, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. This causes the movable mold 102 to be separated from the fixed mold 101, and the mold 100A is opened. In step S57, the ejector 7 is driven to eject the third primary molded product remaining on the movable mold 102 side (inside the cavity) of the mold 100A.

[0230] 6G-6I show an improvement to the molding process of FIGS. 6A-6F.

[0231] In step S58, the secondary molded product α is inserted into the mold 100A, and then the third primary molded product is transported to the top of the injection molding machine 2 and waits there. The ejector 7 continues to hold the third primary molded product from the ejection process (S57) until the insertion (placement) (S72) of the third primary molded product into the mold 100B, which will be described later. In preparation for forming the fourth primary molded product and the tertiary molded product A, the gates are switched in step S59 to allow resin to flow into the cavity of the tertiary molded product A.

[0232] In step S60, the motor 66 is driven to move the movable platen 62 toward the fixed platen 61. This brings the movable mold 102 into close contact with the fixed mold 101, and the mold 100A is closed.

[0233] In step S61, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100A. In step S62, preparations for injection into the mold 100A are made. The resin is measured. When the nozzle 52 is away from the mold 100A, the actuator 55 is driven to move the injection device 5, and the nozzle 52 is brought into contact with the mold 100A.

[0234] In step S63, the molten resin is injected and pressure is maintained. The injection in step S63 is for molding the fourth primary molded product and the tertiary molded product A simultaneously.

[0235] More specifically, the injection unit 5 is driven to fill the cavity in the mold 100A with molten resin from the nozzle 52, and the resin is pushed in at high pressure to compensate for the volume reduction caused by the solidification of the resin. During the process of step S63, the actual clamping force is measured by the sensor 68. During molding, the temperature of the mold 100A gradually increases, causing the mold 100A to thermally expand. There may be a difference between the initial clamping force and the clamping force after a certain period of time has passed. Therefore, the clamping force at the next clamping can be corrected based on the measurement result of the sensor 68. The clamping force is adjusted by driving the motor 67 to adjust the position of the movable platen 63 relative to the tie bar 64. In this way, the initial value of the position of the movable platen 63 relative to the tie bar 64 is corrected according to the measurement result of the sensor 68 to adjust the clamping force, thereby improving the accuracy of the clamping force. The position adjustment of the movable platen 63 relative to the tie bar 64 may be performed at any timing.

[0236] Next, the processes of steps S64 and S66 are performed in parallel with the process of step S65. In step S64, timing of the cooling time of the molded product in the mold 100A is started. In step S65, processes related to the mold clamping device 6 are performed. The fixation of the mold 100A by the fixing mechanism 610 is released. After a predetermined time delay from step S63, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space in which the mold 100A and the mold 100B can be interchanged.

[0237] In step S66, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0238] In step S67, the mold 100A and the mold 100B are replaced. The mold 100A is carried out from the molding operation position 11 to the conveying device 3A, and the mold 100B is carried from the conveying device 3B to the molding operation position 11. The controller 41 transmits an instruction to the controller 42A to carry out the mold 100A, and the controller 42A drives the conveying unit 31 to carry out the mold 100A from the molding operation position 11. The mold 100B moves from the conveying device 3B to the molding operation position 11. When the carrying out of the mold 100A is completed, the controller 42A transmits a signal indicating the carrying out completion to the controller 41. The mold 100A is cooled on the conveying device 3A. The closed state of the mold 100A is maintained by the self-closing portion 103.

[0239] When a signal indicating completion of loading is received, in step S68, the conditions related to the mold 100B are set as the operating conditions for the molding operation. That is, the controller 41 reads out and sets the corresponding operating conditions from among the multiple operating conditions (operating conditions A, B, and C) set in step S1. For example, the thickness (width in the Y direction) of the mold 100B, the mold clamping force, etc. are set as the operating conditions for the current molding operation. Operating conditions such as the injection speed corresponding to the mold 100B are set. Plasticization metering for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100B. At this time, it is not necessary to generate the mold clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100B to the fixed platen 61 and the movable platen 62, respectively.

[0240] In this exemplary embodiment, step S68 is performed after step S67. In another exemplary embodiment, since it may take time to switch the operating conditions, for example, the operating conditions may be switched simultaneously with the instruction to unload the mold 100A.

[0241] In step S69, it is determined whether the cooling of the mold 100B is completed based on whether the cooling time, the measurement of which was started in step S50, has reached a predetermined time.

[0242] In step S70, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. As a result, the movable mold 102 is separated from the fixed mold 101, and the mold 100B is opened. In step S71, the ejector 7 is driven to eject the secondary molded product β remaining on the movable mold 102 side (inside the cavity) of the mold 100B, and after inserting the third primary molded product into the movable mold 102 side of the mold 100B, it is transported to the upper part of the injection molding machine 2 and made to wait. The ejector 7 continues to hold the secondary molded product β from the ejection process (S71) until the insertion (arrangement) (S85) of the secondary molded product β into the mold 100A described later is performed.

[0243] In step S73, the motor 66 is driven to move the movable platen 62 toward the stationary platen 61. This brings the movable mold 102 into close contact with the stationary mold 101, and the mold 100B is closed.

[0244] In step S74, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100B. In step S75, preparations for injection into the mold 100B are made. Here, the actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100B. The secondary molded product γ is molded with the third primary molded product placed in the mold 100B, and in step S76, resin is injected into the third primary molded product to be integrated with it to perform overmolding.

[0245] Next, the processes of steps S77 and S79 are performed in parallel with the process of step S78. In step S77, timing of the cooling time of the molded product in the mold 100B is started. In step S78, processes related to the mold clamping device 6 are performed. The fixation of the mold 100B by the fixing mechanism 610 is released. After a predetermined time delay from step S76, the motor 66 is driven to drive the toggle mechanism 65. This releases the mold clamping force, slightly separates the movable platen 62 from the fixed platen 61, and forms a space in which the mold 100B and the mold 100A can be interchanged.

[0246] In step S79, processing related to the injection unit 5 is performed. For example, pressure holding suck back, nozzle shutoff, and retraction of the injection unit 5 are performed.

[0247] In step S80, the mold 100B and the mold 100A are replaced. The mold 100B is carried out from the molding operation position 11 to the conveying device 3B, and the mold 100A is carried in from the conveying device 3A to the molding operation position 11. The controller 41 transmits an instruction to the controller 42B to carry out the mold 100B, and the controller 42B drives the conveying unit 31 to carry out the mold 100B from the molding operation position 11. The mold 100A moves from the conveying device 3A to the molding operation position 11. When the carrying out of the mold 100B is completed, the controller 42B transmits a signal indicating the carrying out completion to the controller 41. The mold 100B is cooled on the conveying device 3B. The closed state of the mold 100B is maintained by the self-closing portion 103.

[0248] When a signal indicating completion of loading is received, in step S81, conditions related to the mold 100A are set as operating conditions for the molding operation. As in step S54, operating condition C is set as a condition. The reason for setting the condition is for the fifth primary molded product and the tertiary molded product B. Compared to operating condition A, conditions such as mold clamping force and measurement value may be different. Plasticization measurement for the next injection is started. The motor 66 is driven to bring the fixed platen 61 and the movable platen 62 into close contact with the mold 100A. At this time, it is not necessary to generate a mold clamping force that is generated during molding. The fixing mechanism 610 is driven to fix the mold 100A to the fixed platen 61 and the movable platen 62, respectively.

[0249] In step S82, it is determined whether the cooling of the mold 100A is completed based on whether the cooling time, the measurement of which was started in step S64, has reached a predetermined time.

[0250] In step S83, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. The fixed mold 101 is fixed to the fixed platen 61 by a fixing mechanism 610, and the movable mold 102 is fixed to the movable platen 62 by a fixing mechanism 610. This causes the movable mold 102 to be separated from the fixed mold 101, and the mold 100A is opened. In step S84, the ejector 7 is driven to eject the fourth primary molded product and the tertiary molded product A remaining on the movable mold 102 side (inside the cavity) of the mold 100A. In step S85, the secondary molded product β is inserted into the mold 100A, and the fourth primary molded product and the tertiary molded product A are transported to the upper part of the injection molding machine 2 and wait there.

[0251] In step S86, the motor 66 is driven to move the movable platen 62 toward the stationary platen 61. This causes the movable mold 102 to come into close contact with the stationary mold 101, and the mold 100B is closed.

[0252] In step S87, the motor 66 is driven to drive the toggle mechanism 65, and the fixed platen 61 and the movable platen 62 clamp the mold 100B. In step S88, preparations for injection into the mold 100B are made. Here, the actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100B. The secondary molded product γ is molded with the third primary molded product placed in the mold 100B, and in step S89 of FIG. 6, resin is injected into the third primary molded product to be integrated with it to perform overmolding.

[0253] In step S90, it is determined whether the production quantity of the tertiary molded product is less than the planned / target production quantity TH. If the production quantity is less than the planned / target production quantity TH, the process returns to step S67. If the production quantity is equal to or greater than the planned / target production quantity TH, the process ends. <Forming behavior>

[0254] 7A to 7D show molding processes using mold configurations of primary to tertiary molded products by an injection molding system implementing the processes of FIGS. 6A to 6I, and the behavior of the molded products.

[0255] In this embodiment, based on the order of production, the primary molded products are referred to as primary molded product 1, primary molded product 2, and primary molded product 3. When it is not necessary to specify which primary molded product to refer to, primary molded product n is used.

[0256] In this embodiment, the secondary molded product is a molded product generated by performing an injection process on the primary molded product n. Based on the order of generation, the secondary molded products are called secondary molded products α and β. When it is not necessary to specify which secondary molded product to refer to, secondary molded product y is used.

[0257] In this embodiment, the tertiary molded product is a molded product generated by performing an injection process on the secondary molded product y. Based on the order of generation, the tertiary molded products are called tertiary molded product A and tertiary molded product B. When it is not necessary to specify which tertiary molded product to refer to, tertiary molded product x is used.

[0258] FIG. 7A shows a cross-sectional view of the mold 100A and the mold 100B, and the cavity shape of the movable mold 102. The lower part of FIG. 7A shows a cross-section of the mold 100A and the mold 100B parallel to the XY plane. FIG. 7A shows a position in the injection molding machine (A), a mold on the non-operation side of the injection molding machine (B), and a mold on the operation side of the injection molding machine (C). FIG. 7A also shows the position of the ejector during injection molding (D) and the state of the ejector holding the molded product (E).

[0259] 7A shows the filling shapes in the primary molding, secondary molding, and tertiary molding processes, and the final molded product after the tertiary molding. In this embodiment, the molding model is assumed to be a two-cavity molding, but the number of molded products can be any number.

[0260] The mold 100A is a mold for molding a primary molded product 1(n) and a tertiary molded product A(x), which will be described later. The mold 100B is a mold for molding a secondary molded product α(y). A cavity for filling resin is formed in the mold 100A and the mold 100B.

[0261] FIG. 7A shows how, after completing the initial setting step S1, the mold 100A is transported to the molding machine, the mold is clamped for primary molding, the primary molded product 1 is molded, and then the mold is opened after the cooling time has elapsed.

[0262] FIG. 7B shows the ejector lowered to eject the primary molded article 1.

[0263] FIG. 7C shows a remover for removing the primary molded article 1.

[0264] FIG. 7D shows the ejection machine rising after ejecting the primary molded article 1 and then holding the primary molded article 1 while waiting.

[0265] Fig. 7E shows the state after the processes of steps S10 to S16 in Fig. 6B. In this state, the primary molded article 2 is present in the metal mold 100A.

[0266] Fig. 7F shows the process of step S17 in Fig. 6B. Fig. 7F also shows how the mold 100B is transported to the injection molding machine and the mold 100A is transported to the side opposite the operation side of the injection molding machine while the primary molded product 2 in the mold 100A is being cooled.

[0267] FIG. 7G shows how the operating conditions are changed to the settings of 100B after the mold is replaced, and then the mold 100B is opened, after which the ejector 7 holding the primary molded product 1 is lowered.

[0268] Fig. 7H shows the ejector 7 inserting the primary molded article 1 into the metal mold 100B. This corresponds to step S20 in Fig. 6C.

[0269] Figure 7I shows the process in which the ejector 7 rises immediately after the insertion of the primary molded product 1, closes and clamps the mold 100B, and prepares for injection into the mold 100B to mold the secondary molded product α (processing of step S23 in Figure 6C).

[0270] FIG. 7J shows the state of the secondary molded product α formed by overmolding the primary molded product 1, and shows how, after molding, measurement of the cooling time is started, the mold clamping is released to perform a shutoff operation, and the cylinder (not shown) is retracted (the processing up to step S27 in FIG. 6C).

[0271] FIG. 7K shows the process of transporting mold 100B outside of injection molding machine 2, transporting mold 100A into injection molding machine 2, setting injection molding machine 2 to operating condition A for molding primary molded product 3, and checking whether the cooling time for removing primary molded product 2 has been completed.

[0272] FIG. 7L shows a state in which the ejector 7 descends after the mold 100A is opened.

[0273] FIG. 7M shows a remover 7 that removes the primary molded product 2 from the mold 100A.

[0274] FIG. 7N shows the ejector 7 rising after ejecting the primary molded product 2 and waiting for the next insertion.

[0275] 7O shows how the mold is closed and clamped after the ejector 7 is raised to form the primary molded product 3. After molding, measurement of the cooling time is started, the mold is released to perform a shutoff operation, and the cylinder (not shown) is retracted (processing up to step S39 in FIG. 6D).

[0276] Figure 7P shows the process of transporting mold 100A outside of injection molding machine 2, transporting mold 100B into injection molding machine 2, setting injection molding machine 2 to operating condition B for molding secondary molded product β, and checking whether the cooling time for removing secondary molded product α has been completed.

[0277] FIG. 7Q shows a state of the remover 7 descending to remove the secondary molded product α.

[0278] FIG. 7R shows a take-out machine 7 that takes out the secondary molded product α.

[0279] FIG. 7S shows the ejector 7 rising slightly to insert the primary molded article 2.

[0280] FIG. 7T shows the ejector 7 that inserts the primary molded product 2 into the mold 100B.

[0281] FIG. 7U shows how the ejector 7 rises and waits after the primary molded product 2 is inserted, closes and clamps the mold, and prepares for injection to mold the secondary molded product β.

[0282] 7V shows how a secondary molded product β is molded by overmolding the primary molded product 2. After molding, measurement of the cooling time is started, the mold clamping is released to perform a shutoff operation, and the cylinder (not shown) is retracted (processing up to step S52 in FIG. 6E).

[0283] Figure 7W shows the process of transporting mold 100B outside of injection molding machine 2, transporting mold 100A into injection molding machine 2, setting injection molding machine 2 to operating condition C for molding a tertiary molded product, and checking whether the cooling time for removing primary molded product 3 has been completed.

[0284] FIG. 7X shows the ejector 7 descending to eject the primary molded article 3.

[0285] FIG. 7Y shows how the primary molded product 3 is removed and the secondary molded product α is inserted into the cavity for tertiary molding.

[0286] 7Z shows the unloader 7 rising and waiting after inserting the secondary molded product α. At this time, the gate of the mold 100A is switched, and the primary molded product and the tertiary molded product are molded simultaneously.

[0287] Figure 7AA shows the primary molded product 4 and the tertiary molded product A that have been molded by closing and clamping the mold 100A in preparation for injection, and shows the process of starting to measure the cooling time, releasing the clamping to perform the shutoff operation, and retracting the cylinder (not shown) (processing up to step S66 in Figure 6G).

[0288] Figure 7AB shows the process of transporting mold 100A outside of injection molding machine 2, transporting mold 100B into injection molding machine 2, setting injection molding machine 2 to operating condition B for molding secondary molded product γ, and checking whether the cooling time for removing secondary molded product β has been completed.

[0289] FIG. 7AC shows the remover 7 descending to remove the secondary formed product β.

[0290] FIG. 7AD shows a take-out machine 7 that takes out the secondary formed product β.

[0291] FIG. 7AE shows a demolder 7 that inserts the primary molded product 3 into the mold 100B.

[0292] FIG. 7AF shows the state in which the ejector 7 rises and waits after the primary molded product 3 has been inserted, and then the mold is closed and clamped, followed by preparation for injection to mold the secondary molded product γ.

[0293] FIG. 7AG shows the process of overmolding the primary molded product 3 to form a secondary molded product γ, starting to measure the cooling time after molding, releasing the mold clamping to perform a shutoff operation, and retracting the cylinder (not shown) (the process up to step S79 in FIG. 6H).

[0294] Figure 7AH shows the process of transporting mold 100B outside of injection molding machine 2, transporting mold 100A into injection molding machine 2, setting injection molding machine 2 to operating condition C for molding a tertiary molded product, and checking whether the cooling time for removing primary molded product 4 and tertiary molded product A has been completed.

[0295] FIG. 7AI shows the ejector 7 descending to eject the primary molded article 4 and the tertiary molded article A.

[0296] FIG. 7AJ shows a take-out machine 7 that takes out the primary molded product 4 and the tertiary molded product A.

[0297] FIG. 7AK shows a state in which the extractor 7 descends to insert the secondary formed product β.

[0298] FIG. 7AL shows how the primary molded product 3 is removed and the secondary molded product β is inserted into a cavity for tertiary molding.

[0299] FIG. 7AM shows the state in which the ejector rises and waits, closes and clamps the mold, and prepares for injection to mold primary molded product 5 and tertiary molded product B.

[0300] FIG. 7AN shows how a primary molded product 5 and a tertiary molded product B are formed by overmolding a secondary molded product β.

[0301] FIG. 7AO shows a state in which the tertiary molded product A is transported from the take-out machine 7 to a finished product storage location, and it is determined whether the actual production quantity is less than the scheduled / target production quantity (Step S90 in FIG. 6I).

[0302] If the predetermined production quantity TH has not been reached, the process returns to FIG. 7A, and the processes associated with FIGS. 7A to 7AO are repeated.

[0303] As described above, in step S1 of Fig. 6, the controller 41 can set the temperatures for both the mold 100A and the mold 100B based on an instruction from an operator. In another exemplary embodiment, the mold temperature for manufacturing an inner layer part located in the middle layer (secondary molding area in the example of Fig. 7A) of a final molded product manufactured by overmolding is set lower than the mold temperature for manufacturing a surface layer part located outside the inner layer part (primary and tertiary molding areas in the example of Fig. 7A).

[0304] The temperature of the mold 100B can be set in FIG. 7G, but in another exemplary embodiment, the temperature is set as low as possible, for example, at a temperature at which the resin to be molded can be injected and filled into the mold. For example, when overmolding a thick-walled molded product, the secondary molded product area that serves as an intermediate layer does not affect the surface accuracy and dimensions of the final molded product. Therefore, in molding the second layer, the resin can be injected and filled without the need to monitor the surface accuracy and dimensions of the molded product, allowing for an increased cooling rate.

[0305] Intentionally varying the thickness of the primary, secondary, or tertiary molding zones can be an effective technique. For example, the thickness of the secondary molding zone can be made thicker than that of the primary and tertiary molding zones, allowing thicker parts to be molded in a shorter time by forming the thicker parts at a lower mold temperature. The thinner primary and tertiary molding zones, which are formed at a higher temperature, reduce the cooling time and increase productivity.

[0306] When the secondary molding region of the molded product has a thicker wall thickness, the secondary molded product α can have a thickness that accounts for most of the part thickness to be finally obtained. In Fig. 7Z, similarly to the case of molding a primary molded product, by setting the mold 100A to, for example, -5°C to -30°C of the thermal deformation temperature of the molding resin, a tertiary molded product with high transferability and excellent surface accuracy can be molded.

[0307] As described above, by providing a temperature difference between the mold 100A and the mold 100B during molding, it becomes possible to mold thick-walled parts with higher productivity.

[0308] In this embodiment, the mold 100A that forms the first and third layers is set at a high temperature, and the mold 100B that forms the second layer is set at a low temperature. In another exemplary embodiment, the mold 100A can be set at a low temperature and the mold 100B can be set at a high temperature, depending on the intended use of the molding process.

[0309] In step S1 of FIG. 6A, when the operator sets the resin injection temperature for each molded product, by specifying a part in the intermediate region (in this example, the secondary molded product) from among each molded product, the resin temperature can be automatically determined so that the resin temperature of the secondary molded product is lower than the resin temperatures of the primary molded product / tertiary molded product (primary molded product, secondary molded product and tertiary molded product). definition

[0310] In the description, specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. In other instances, well-known methods, procedures, components, and circuits have not been described in detail to avoid unnecessarily lengthening the present disclosure.

[0311] As used herein, when an element or portion is referred to as being "on," "on," "connected," or "coupled" to another element or portion, it is understood that it may be "on," "on," "connected," or "coupled" directly to that other element or portion, or there may be intervening elements or portions. In contrast, when an element is referred to as being "directly on," "directly connected," or "directly coupled" to another element or portion, there are no intervening elements or portions. When the term "and / or" is used, it includes any and all combinations of one or more of the associated listed items, if any.

[0312] Spatially relative terms such as "under," "beneath," "below," "lower," "above," "upper," "proximal," "distal," and the like may be used herein for ease of description in describing the relationship of an element or feature shown in the various figures to another element or feature(s). However, it should be understood that these spatially relative terms are intended to encompass various orientations of the device in use or operation in addition to the orientation shown in the figures. For example, if the device in the figures were inverted, elements described as "below" or "beneath" other elements or features would be oriented "above" those other elements or features. Thus, a relative spatial term such as "below" can encompass both an orientation above and below. The device may be otherwise oriented (rotated 90 degrees or to other orientations) and the spatially relative descriptors used herein should be interpreted accordingly. Similarly, the relative spatial terms "proximal" and "distal" may be interchangeable where applicable.

[0313] As used herein, the term "about" means, for example, within 10%, within 5%, or less. In some embodiments, the term "about" can also mean within the error of measurement.

[0314] In this specification, terms such as first, second, third, etc. may be used to describe various elements, components, regions, portions, and / or sections. It should be understood that these elements, components, regions, portions, and / or sections are not limited by these terms. These terms are merely used to distinguish one element, component, region, portion, or section from another region, portion, or section. Thus, a first element, component, region, portion, or section discussed below can also be referred to as a second element, component, region, portion, or section without departing from the teachings of this specification.

[0315] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting. The use of the terms "a," "an," "the," and similar referents in the context of describing the present disclosure (especially in the context of the appended claims) shall be construed to include both the singular and the plural, unless otherwise indicated herein or otherwise clear from the context. The terms "comprising," "having," "includes," "including," and "containing" shall be construed as open-ended terms (i.e., meaning "including, but not limited to"), unless otherwise stated. In particular, when these terms are used herein, they specify the presence of the described features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof not expressly stated. The description of ranges of values ​​herein is merely intended to serve as a shorthand notation for referring individually to each separate value falling within the range, and each separate value is incorporated herein as if it were individually set forth herein, unless otherwise indicated herein. For example, if a range of 10-15 is disclosed, 11, 12, 13, and 14 are also disclosed. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clear from the context. The use of any examples or exemplary language (e.g., "such as") provided herein is intended merely to make the disclosure more clear, and does not limit the scope of the disclosure unless otherwise stated in the claims. No language in this specification should be construed as indicating that any element not recited in the claims is essential to the practice of the disclosure.

[0316] It should be understood that the methods and configurations of the present disclosure can be incorporated in the form of various embodiments, only a few of which are disclosed herein. Variations of those embodiments will be apparent to those skilled in the art upon reading the above description. The inventors anticipate that those skilled in the art will adopt such variations as necessary, and intend that the present disclosure be practiced otherwise than as specifically described herein. Accordingly, the present disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, the present disclosure encompasses any combination of the above-described elements in all possible variations thereof, unless otherwise indicated herein or otherwise apparent from the context.

Claims

1. an injection molding machine that injects resin into a mold; a transport device configured to move a mold between a first location within the injection molding machine and a second location outside the injection molding machine; A controller; An insertion unit; An injection molding system comprising: The controller is configured to control the transport device so as not to move the first mold until the injection molding machine performs N injection processes (N≧2) on the first mold, and is further configured to control the transport device to move the first mold from the first position to the second position after the N injection processes on the first mold, and to move a second mold outside the injection molding machine into the injection molding machine; The insertion unit is configured to insert one of the first molded products obtained based on the N injection processes in the first mold into the second mold, and to obtain a second molded product by injecting resin into the second mold with the first molded product inserted therein by the injection molding machine. Injection molding system.

2. inserting the second molded product into the first mold, and injecting a resin into the first mold with the second molded product inserted therein by the injection molding machine to obtain a third molded product. The injection molding system of claim 1 .

3. Further comprising a holding unit configured to hold the first molded article until the first molded article is inserted into the second mold, the holding unit configured to hold the second molded article until the second molded article is inserted into the first mold. The injection molding system of claim 2 .

4. A cooling process for cooling the resin injected into the first mold is performed in the injection molding machine for at least one first molded product among the N first molded products, and the cooling process is performed outside the injection molding machine for other first molded products among the N first molded products. The injection molding system of claim 2 .

5. N is 3, and the controller is configured to control the conveying device so as not to move the second mold from the first position after the second mold is moved to the first position until two injection processes are performed with the second mold to obtain two second molded products, and to control the conveying device so as to move the second mold from the first position to the outside of the injection molding machine after the two injection processes with the second mold by the injection molding machine. The injection molding system of claim 2 .

6. N is 2, and the controller is configured to control the conveying device to move the second mold from the first position to the outside of the injection molding machine after one injection process of the second mold by the injection molding machine after moving the second mold to the first position. The injection molding system of claim 2 .

7. a removal unit for removing the first molded article from the first mold, and a holding unit configured to hold the first molded article until the first molded article is inserted into the second mold. The injection molding system of claim 2 .

8. the removal unit is configured to remove the second molded product from the second mold, and the insertion unit is configured to insert the second molded product into the first mold.

8. The injection molding system of claim 7.

9. a second transport device configured to move the second mold between the first location within the injection molding machine and a third location outside the injection molding machine while the transport device moves the first mold between the first and second locations; The injection molding system of claim 2 .

10. the controller is configured to control a temperature for an injection molding process such that a temperature of the first mold into which the resin is injected is higher than a temperature of the second mold into which the resin is injected. The injection molding system of claim 2 .

11. an injection molding machine that injects resin into a mold; a transport device configured to move a mold between a first location within the injection molding machine and a second location outside the injection molding machine; A controller; An insertion unit; An injection molding system comprising: the insertion unit is configured to insert a first molded product obtained based on an injection process in a first mold into a second mold, and to inject a resin into the second mold into which the first molded product has been inserted by the injection molding machine, thereby obtaining a second molded product; the controller is configured to control a temperature related to an injection molding process such that a temperature of the first mold into which a first resin is injected is higher than a temperature of the second mold into which a second resin is injected; the insertion unit is configured to insert the second molded product into the first mold and to inject resin into the first mold with the second molded product inserted therein by the injection molding machine to obtain a third molded product; the controller controls the temperature of the second mold so that the temperature of the second mold is lower than the temperature of the first mold into which the resin is injected to obtain the third molded product; Injection molding system.

12. The first mold includes a first cavity configured to obtain the first molded product, a second cavity configured to obtain the third molded product, and a gate provided in a flow path between the first cavity and the second cavity and configured to allow or prevent the resin from flowing from the first cavity to the second cavity.

12. An injection molding system according to any one of claims 2 to 11.

13. 1. An injection molding machine for injecting resin into a mold, the injection molding machine operating with a transport device configured to move the mold between a first position within the injection molding machine and a second position outside the injection molding machine; A controller; An insertion unit; Equipped with The first mold is not moved by the conveying device until the injection molding machine performs N injection processes (N≧2) with the first mold, and after the N injection processes with the first mold, the first mold is moved from the first position to the second position by the conveying device so that a second mold located outside the injection molding machine is moved into the injection molding machine; the controller is configured to control the insertion unit so as to insert one of the first molded products obtained based on the N number of injection processes in the first mold into the second mold, and the injection molding machine injects resin into the second mold into which the first molded product has been inserted to obtain a second molded product. Injection molding machine.

14. the controller is configured to control the insertion unit to insert the second molded product into the first mold, and the injection molding machine injects resin into the first mold into which the second molded product has been inserted to obtain a third molded product.

14. The injection molding machine according to claim 13.

15. a holding unit configured to hold the first molded part until the first molded part is inserted into the second mold, the holding unit configured to hold the second molded part until the second molded part is inserted into the first mold.

15. The injection molding machine of claim 14.

16. A cooling process for cooling the resin injected into the first mold is performed within the injection molding machine for at least one of the first molded products of the N times, and the cooling process for the other first molded products of the N times is performed outside the injection molding machine.

15. The injection molding machine of claim 14.

17. the controller is configured to control a temperature for an injection molding process such that a temperature of the first mold into which the resin is injected is higher than a temperature of the second mold into which the resin is injected.

15. The injection molding machine of claim 14.

18. The first mold includes a first cavity configured to obtain the first molded product, a second cavity configured to obtain the third molded product, and a gate provided in a flow path between the first cavity and the second cavity and configured to allow or prevent the resin from flowing from the first cavity to the second cavity.

18. An injection molding machine according to any one of claims 14 to 17.

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