Molding die, resin molding apparatus, and resin molding system

Abstract

To provide a manufacturing method of a resin molded product capable of suppressing adhesion of a resin to a terminal due to resin leakage even when resin molding is performed in a state that a molding object is placed in a molding die so that a direction orthogonal to an extending direction of a flat face of the terminal having a flat face extending from one end of a main body part of a molding object becomes perpendicular to a mold surface of the molding die.SOLUTION: A molding die comprises an upper molding die 20a and a lower molding die 20b. The upper molding die 20a or the lower molding die 20b comprises a cavity block 21 in which a cavity for housing a main body part 3a is formed, and a terminal housing part 200 which houses a terminal 3b. The terminal housing part 200 comprises a terminal arrangement block 23, and an elastomeric resin 4 between the cavity block 21 and the terminal arrangement block 23. The terminal housing part 200 has a slit 22.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a mold, a resin molding apparatus, and a resin molding system.

Background Art

[0002] For example, Patent Document 1 describes a method for manufacturing a resin-molded coil in which a terminal pin extending from the base of a coil is passed through a through-hole in a bottom plate made of a thermoplastic synthetic resin, and resin molding is performed with the bottom plate attached to the coil.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the method for manufacturing a resin-molded coil described in Patent Document 1, when the terminal pin of the coil has a flat surface, it becomes difficult for the bottom plate made of a thermoplastic synthetic resin to adhere to the terminal pin, and resin may leak between the terminal pin and the bottom plate, causing resin to adhere to the terminal pin. In particular, resin leakage is likely to occur when resin molding is performed with the coil installed in the mold such that the direction perpendicular to the direction in which the flat surface of the terminal pin extends is perpendicular to the mold surface.

Means for Solving the Problems

[0005] According to the embodiments disclosed herein, a mold for resin-molding a molding object including a main body portion and a terminal having a flat surface extending from one end of the main body portion, the mold being for resin-molding the molding object with the molding object installed such that a direction orthogonal to the direction in which the flat surface extends is perpendicular to the mold surface of the mold, the mold including an upper mold and a lower mold, and either the upper mold or the lower mold including a cavity block in which a cavity for accommodating the main body portion is formed, and a terminal accommodating portion for accommodating the terminal, the terminal accommodating portion including a terminal arrangement block and an elastic resin between the cavity block and the terminal arrangement block, and a slit being provided in the terminal accommodating portion.

[0006] According to the embodiments disclosed herein, a resin molding apparatus including the above-described mold can be provided.

[0007] According to the embodiments disclosed herein, a resin molding system including the above-described resin molding apparatus can be provided.

Effects of the Invention

[0008] According to the embodiments disclosed herein, even when resin molding is performed with the molding object installed in the mold such that a direction orthogonal to the direction in which the flat surface of the terminal having a flat surface extending from one end of the main body portion of the molding object extends is perpendicular to the mold surface of the mold, it is possible to provide a mold, a resin molding apparatus, and a resin molding system that can suppress adhesion of resin to the terminal due to resin leakage.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

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Figure 7

Figure 8

MODE FOR CARRYING OUT THE INVENTION

[0010] Hereinafter, embodiments will be described. In the drawings used for the description of the embodiments, the same reference numerals denote the same parts or corresponding parts.

[0011] <Resin Molding System> FIG. 1 is a schematic plan view of an example of a resin molding system including a resin molding apparatus according to an embodiment. The resin molding system 100 includes a resin molding apparatus 20 including a molding die composed of an upper mold and a lower mold 20b, which will be described later. The resin molding apparatus 20 enables resin molding of a coil 3, which is an example of a molding object, using the molding die. The resin molding apparatus 20 includes a transfer mechanism having a plunger for supplying resin from a pot 39 to a cavity, and a clamping mechanism 48.

[0012] The resin molding system 100, in addition to the resin molding apparatus 20, includes a CPU 1 as a central control unit, a storage unit 8 that stores control information such as control programs and stop processing procedures of the resin molding system 100, a drive mechanism that drives each of the components described later, and a touch panel 9 (an example of an input unit) that receives operation commands and input of abnormality processing related information from the user and displays various output information of the resin molding system 100. The CPU 1 realizes a control unit 10 that controls the operations of each part of the resin molding system 100, an abnormality detection unit 11 that detects abnormalities in the drive mechanism, and a timing unit 12 that counts the elapsed time by executing programs and the like stored in the storage unit 8.

[0013] The resin molding system 100 is configured by connecting an in-module M1 having an in-magazine 7 and the like for accommodating a plurality of coils 3, a mold module M2 having a resin molding apparatus 20, and an out-module M3 having an out-magazine 72 for accommodating the resin molded product 31 manufactured by the resin molding apparatus 20. The in-module M1, the mold module M2, and the out-module M3 are provided with guides G linearly arranged across each of these modules. The guide G is a rail-like member for running a loader 40 and an unloader 44 described later. Note that the resin molding system 100 shown in FIG. 1 includes two mold modules M2, but the resin molding system 100 may include only one mold module M2 or may include three or more mold modules M2.

[0014] The drive mechanism of the resin molding system 100 may include, for example, a loader 40, a supply unit 42, and an unloader 44. The loader 40 is a transport mechanism for carrying the object to be molded 3 into the resin molding apparatus 20. The supply unit 42 is a transport mechanism for pushing out the coil 3 from the in-magazine 7 and transporting it to the alignment mechanism 70. The unloader 44 is a transport mechanism for carrying out the resin molded product 31 from the resin molding apparatus 20.

[0015] <Object to be molded> FIG. 2 shows a schematic partial perspective view of a coil 3 which is an example of an object to be molded used in the resin molding apparatus 20 of the embodiment. As shown in FIG. 2, the coil 3 which is an example of the object to be molded includes a main body portion 3a and a terminal 3b having a rectangular flat surface 3c extending in one direction from one end of the main body portion 3a. In the present specification, the "flat surface" means, for example, as shown in FIG. 2, a plane included in the terminal 3b and is one of two planes orthogonal (intersecting) to the direction in which the terminal 3b extends. More specifically, the "flat surface" means a plane having a longer length in the direction orthogonal to the direction in which the terminal 3b extends among these two planes. Further, in the present specification, the "thickness of the terminal" means the shortest length of the length defining the area of the surface having the minimum area among the surfaces constituting the terminal 3b.

[0016] The ratio of the longer length of the lengths L1 and L2 of the terminal 3b to the thickness t of the terminal 3b ((longer length of the lengths L1 and L2 [mm]) / (thickness t [mm])) can be, for example, 2 or more and 80 or less. For example, the thickness t of the terminal 3b can be about 1.4 mm. Also, the length L1 of the terminal 3b can be, for example, about 50 mm. Also, the length L2 of the terminal 3b can be, for example, about 16 mm.

[0017] <Lower mold> FIG. 3 shows a schematic perspective view of an example of the lower mold 20b of the resin molding apparatus 20 of the embodiment. In the example shown in FIG. 3, the lower mold 20b of the resin molding apparatus 20 in a state where the coil 3 shown in FIG. 2 is installed is shown. As shown in FIG. 3, the lower mold 20b is installed such that the direction 3f orthogonal to the extending direction 3e of the flat surface 3c of the terminal 3b of the coil 3 is perpendicular to the mold surface 22d of the lower mold 20b.

[0018] As shown in Fig. 3, the lower molding die 20b includes a cavity block 21 in which a cavity for accommodating the main body portion 3a of the coil 3 is formed, and a terminal accommodating portion 200 for accommodating the terminals 3b of the coil 3. The portion of the cavity block 21 on the side of the terminal accommodating portion 200 (hereinafter referred to as "cavity block portion 21a") has the same height (length in the direction parallel to the flat surface of the terminal 3b) as the terminal accommodating portion 200. A first slit 22a is formed in the cavity block portion 21a, as will be described later. In the present embodiment, the cavity block portion 21a in which the first slit 22a is formed is configured separately from the cavity block 21 of the portion where the cavity is formed, but they may be integrally formed. Further, the terminal accommodating portion 200 includes an elastic resin 4 and a terminal arrangement block 23. The elastic resin 4 is located between the cavity block 21 (or the cavity block portion 21a) and the terminal arrangement block 23.

[0019] Also, as shown in Fig. 3, a slit 22 extending in a predetermined direction (in the present embodiment, linearly extending in one direction of the extending direction 3e of the flat surface 3c of the terminal 3b of the coil) is provided in the cavity block portion 21a of the cavity block 21 that contacts the terminal accommodating portion 200, the elastic resin 4, and the terminal arrangement block 23. The slit 22 includes a first slit 22a provided in the cavity block portion 21a, a second slit 22c provided in the terminal arrangement block 23, and a third slit 22b provided in the elastic resin 4. In the present embodiment, the first slit 22a, the second slit 22c, and the third slit 22b each linearly extend in the extending direction 3e of the flat surface 3c of the terminal 3b of the coil from the side of the cavity block 21 where the cavity is formed.

[0020] The wall surfaces of the slit 22 (including the respective wall surfaces of the first slit 22a, the second slit 22c, and the third slit 22b) are configured to face the flat surface 3c of the terminal 3b of the coil 3 so that the terminal 3b of the coil 3 can be accommodated within the slit 22. Here, the wall surface of the first slit 22a is composed of the opposing surfaces of the cavity block portion 21a along the extending direction 3e of the first slit 22a. The wall surface of the second slit 22c is composed of the opposing surfaces of the terminal arrangement block 23 along the extending direction 3e of the second slit 22c. The wall surface of the third slit 22b is composed of the opposing surfaces of the elastic resin 4 along the extending direction 3e of the third slit 22b.

[0021] The elastic resin 4 can contain a resin that elastically deforms, for example, a silicone rubber or a resin containing fluorine (fluororesin). It is more preferable to contain a fluororesin that can withstand high temperatures and high pressures during resin molding. Examples of the fluororesin include polytetrafluoroethylene (PTFE), tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), tetrafluoroethylene-hexafluoropropylene copolymer (FEP), tetrafluoroethylene-ethylene copolymer (ETFE), and rubbers containing fluorine atoms (FKM, FPM, FEPM, FFKM, etc.). The cavity block 21 and the terminal arrangement block 23 can contain, for example, a metal.

[0022] FIG. 4 shows a schematic plan perspective view of an example when viewing the terminal accommodating portion 200 from above before fixing the position of the elastic resin 4 shown in FIG. 3. In the plan view shown in FIG. 4, the terminal arrangement block 23 is configured to surround the elastic resin 4 in a U-shape. That is, in the plan view, three sides of the rectangular elastic resin 4 are surrounded by the terminal arrangement block 23, and the remaining one side faces the rectangular cavity block portion 21a.

[0023] Also, as shown in FIG. 4, the terminal housing portion 200 further includes a pressing plate 24 between the elastic resin 4 and the terminal arrangement block 23. The pressing plate 24 is configured to be movable in the direction 3e in which the slit 22 extends, and the elastic resin 4 can be pressed by the movement of the pressing plate 24. The pressing plate 24 is also provided with a slit (a fourth slit 24a) along the direction 3e in which the slit 22 extends. The width of the fourth slit 24a can be set equal to the width d3 of the second slit 22c described later.

[0024] Also, as shown in FIG. 4, the terminal arrangement block 23 is provided with a through hole 26 that penetrates the terminal arrangement block 23 in the direction 3e in which the slit 22 extends. The terminal housing portion 200 further includes a pressing member 25 configured to be movable inside the through hole 26 in the direction 3e in which the slit 22 extends. The pressing member 25 is configured to be able to press the pressing plate 24 in the direction 3e in which the slit 22 extends.

[0025] As the pressing member 25, for example, a fastening member such as a male screw can be used. When a male screw is used as the pressing member 25, for example, by cutting a female screw on the inner surface of the through hole 26, the pressing member 25 can be fitted into the through hole 26 and moved in the direction 3e in which the slit 22 extends while rotating the pressing member 25 toward the pressing plate 24. Then, as shown in the schematic plan view of FIG. 5, the movement of the pressing member 25 progresses, the tip of the pressing member 25 is exposed from one end of the through hole 26 and presses the pressing plate 24 at a point, and subsequently the pressing plate 24 can press the elastic resin 4 against the cavity block 21 in a surface manner. Thus, in the present embodiment, the pressing plate 24 can fix the position of the elastic resin 4 by pressing the elastic resin 4 against the cavity block 21 as evenly as possible in a plane.

[0026] Note that it is necessary to replace the elastic resin 4 when resin molding is repeated. In this case, conversely, as shown in FIG. 4 for example, the pressing member 25 can be moved in a direction away from the pressing plate 24 while rotating the pressing member 25. Thereby, the pressing of the pressing plate 24 by the pressing member 25 can be released, and further, the pressing of the elastic resin 4 against the cavity block 21 by the pressing plate 24 can be released. Thereafter, the elastic resin 4 can be taken out from the terminal housing portion 200, a new elastic resin 4 can be installed, and the position of the new elastic resin 4 can be fixed by the same method as described above. Thus, in the present embodiment, the elastic resin 4 can be replaced while the mold is attached to the resin molding apparatus 20.

[0027] The width d2 of the third slit 22b shown in FIGS. 4 and 5 can be made narrower than the width d1 of the first slit 22a. By making the width d2 of the third slit 22b narrower than the width d1 of the first slit 22a, it is possible to more effectively suppress the adhesion of resin to the terminal 3b due to resin leakage during resin molding of the object to be molded. Further, the width d3 of the second slit 22c can be equal to the width d2 of the third slit 22b or wider than the width d2 of the third slit 22b. Furthermore, the width d3 of the second slit 22c can be made wider than the width d1 of the first slit 22a. When the width d3 of the second slit 22c is larger, it is possible to prevent the tip of the terminal 3b from contacting the lower mold 20b when the terminal 3b of the coil 3 is arranged on the lower mold 20b, and it is possible to prevent the lower mold 20b from being damaged. Note that the width d1 of the first slit 22a, the width d3 of the second slit 22c, and the width d2 of the third slit 22b each mean the width in a direction perpendicular to the extending direction 3e of the slit 22 and parallel to the mold surface 22d of the lower mold 20b.

[0028] <Upper mold> FIG. 6 shows a schematic perspective view of an example of the upper mold used in the resin molding apparatus 20 of the embodiment. As shown in FIG. 6, the upper mold 20a includes a cavity block 33 in which a cavity for accommodating the main body 3a of the coil 3 is formed, and a slit 32 for accommodating the terminal 3b of the coil 3. Here, the cavity of the upper mold 20a is disposed at a position corresponding to the cavity of the lower mold 20b. Also, the slit 32 of the upper mold 20a is disposed at a position corresponding to the slit 22 of the lower mold 20b. The slit 32 of the upper mold 20a may include a first slit 32a provided at a position corresponding to the first slit 22a of the lower mold 20b, a third slit 32b provided at a position corresponding to the third slit 22b of the lower mold 20b, and a second slit 32c provided at a position corresponding to the second slit 22c of the lower mold 20b.

[0029] In the present embodiment, the case where the lower mold 20b has the configuration shown in FIGS. 3 to 5 and the upper mold 20a has the configuration shown in FIG. 6 has been described. However, the lower mold 20b may have the configuration shown in FIG. 6 and the upper mold 20a may have the configuration shown in FIGS. 3 to 5. That is, either one of the upper mold 20a or the lower mold 20b may have the configuration shown in FIGS. 3 to 5.

[0030] Also, in the present embodiment, the case where the lower mold 20b has the slit 22 and the upper mold 20a has the slit 32 has been described. In this case, since the slit for accommodating the terminal 3b of the coil 3 is formed by being divided into the upper and lower molds, when the length L2 (width of the flat surface 3c) or the length L1 (length of the flat surface 3c) of the terminal 3b is long, there is an advantage that it is easy to insert and arrange the terminal 3b into the slit. However, the slit 32 of the upper mold 20a is not essential, and the slit for accommodating the terminal 3b of the coil 3 may be formed only in the lower mold 20b.

[0031] <Resin molding> Thereafter, for example, as shown in the schematic plan view of FIG. 7, after the upper mold 20a and the lower mold 20b are clamped, the resin molding of the coil 3 is performed. Thereafter, by opening the upper mold 20a and the lower mold 20b, a resin molded product 31 as shown in the schematic perspective view of FIG. 8, for example, can be manufactured.

[0032] In the present embodiment, while the main body portion 3a of the coil 3 of the resin molded product 31 can be resin-coated, the terminal 3b having the flat surface 3c extending from one end of the main body portion 3a can be prevented from being resin-coated. This is because, in the present embodiment, by pressing the elastic resin 4 against the cavity block portion 21a, the elastic force of the elastic resin 4 can be utilized to bring the elastic resin 4 into close contact with the cavity block portion 21a. Also, the elastic force of the elastic resin 4 can be utilized to bring the elastic resin 4 into close contact with the terminal 3b. Thereby, in the present embodiment, since the resin molding of the main body portion 3a of the coil 3 can be performed in a state where the elastic resin 4 is in close contact with the cavity block portion 21a and the elastic resin 4 is in close contact with the terminal 3b, the occurrence of resin leakage to the outside (terminal arrangement block 23 side) from the cavity block portion 21a can be suppressed. Thereby, in the present embodiment, even when resin molding is performed with the coil 3 installed in the mold such that the direction 3f orthogonal to the extending direction 3e of the flat surface 3c of the terminal 3b having the flat surface 3c extending from one end of the main body portion 3a of the coil 3, which is an example of the object to be molded, is perpendicular to the mold surface of the mold, it is possible to suppress the adhesion of resin to the terminal due to resin leakage.

[0033] Also, in the present embodiment, for example, when the above-described fluororesin is used for the elastic resin 4, it becomes possible to smoothly insert and arrange the terminal 3b in the third slit 22b provided in the elastic resin 4. Further, in the present embodiment, for example, as described above, it is also possible to replace the elastic resin 4 while the mold is attached to the resin molding apparatus 20.

[0034] <Supplementary Note> (Disclosure 1) The mold of Disclosure 1 is a mold for resin-molding an object to be molded that includes a main body portion and a terminal having a flat surface extending from one end of the main body portion, and is a mold for resin-molding the object to be molded with the object to be molded installed such that the direction orthogonal to the direction in which the flat surface extends is perpendicular to the mold surface of the mold. The mold includes an upper mold and a lower mold. Either one of the upper mold or the lower mold includes a cavity block in which a cavity for accommodating the main body portion is formed, and a terminal accommodating portion for accommodating the terminal. The terminal accommodating portion includes a terminal arrangement block and an elastic resin between the cavity block and the terminal arrangement block. The terminal accommodating portion is provided with a slit, and is a mold.

[0035] (Disclosure 2) The mold of Disclosure 2 is the mold of Disclosure 1, in which the elastic resin contains a fluororesin.

[0036] (Disclosure 3) The mold of Disclosure 3 is the mold of Disclosure 1 or Disclosure 2, in which either one of the molds is the lower mold.

[0037] (Disclosure 4) The mold of Disclosure 4 is any one of the molds of Disclosure 1 to Disclosure 3, in which the terminal arrangement block is configured to surround the elastic resin in a U-shape in plan view.

[0038] (Disclosure 5) The mold of Disclosure 5 is the mold of Disclosure 4, in which the terminal accommodating portion further includes a pressing plate between the elastic resin and the terminal arrangement block, the pressing plate is movable in the direction in which the slit extends, and the elastic resin can be pressed by the movement of the pressing plate.

[0039] (Disclosure 6) The mold of Disclosure 6 is the mold of Disclosure 5, wherein a through hole penetrating the terminal arrangement block in the direction in which the slit extends is provided in the terminal arrangement block, and the terminal accommodation portion further includes a pressing member configured to be movable in the direction in which the slit extends inside the through hole, and the pressing member is configured to be able to press the pressing plate in the direction in which the slit extends.

[0040] (Disclosure 7) The mold of Disclosure 7 is the mold of Disclosure 6, wherein the pressing plate is configured to be able to press the elastic resin on a surface, and the pressing member is configured to be able to press the pressing plate at a point.

[0041] (Disclosure 8) The mold of Disclosure 8 is the mold of Disclosure 6 or Disclosure 7, wherein a female thread is cut on the inner surface of the through hole, the pressing member is a male thread, and the pressing member is configured to be movable inside the through hole by rotating the pressing member.

[0042] (Disclosure 9) The mold of Disclosure 9 is the mold of any one of Disclosures 1 to 8, wherein the slit includes a first slit provided in the cavity block, a second slit provided in the terminal arrangement block, and a third slit provided in the elastic resin.

[0043] (Disclosure 10) The mold of Disclosure 10 is the mold of Disclosure 9, wherein the width of the third slit is narrower than the width of the first slit.

[0044] (Disclosure 11) The mold of Disclosure 11 is the mold of Disclosure 9 or Disclosure 10, wherein the width of the second slit is wider than each of the width of the first slit and the width of the third slit.

[0045] (Disclosure 12) The resin molding apparatus of Disclosure 12 is a resin molding apparatus including the mold of any one of Disclosures 1 to 11.

[0046] (Disclosure 13) The resin molding system of Disclosure 13 is a resin molding system including the resin molding apparatus of Disclosure 12.

[0047] Although the embodiments have been described as above, it has been initially planned to appropriately combine the configurations of the above-described embodiments.

[0048] The embodiments disclosed this time should be considered as illustrative in all respects and not restrictive. The scope of the present invention is shown not by the above description but by the claims, and it is intended that all modifications within the meaning and scope equivalent to the claims are included.

Explanation of Reference Numerals

[0049] 1 CPU, 3 coil, 3a main body, 3b terminal, 3c flat surface, 4 elastic resin, 7 in-magazine, 8 storage unit, 9 touch panel, 10 control unit, 11 abnormality detection unit, 12 timing unit, 20 resin molding apparatus, 20a upper mold, 20b lower mold, 21, 33 cavity block, 21a cavity block portion, 22, 32 slit, 22a, 32a first slit, 22b, 32b third slit, 22c, 32c second slit, 22d mold surface, 23 terminal arrangement block, 24 pressing plate, 24a fourth slit, 25 pressing member, 26 through hole, 31 resin molded product, 39 pot, 40 loader, 42 supply unit, 44 unloader, 48 mold clamping mechanism, 70 alignment mechanism, 72 out-magazine, 100 resin molding system, 200 terminal housing portion.

Claims

1. A mold for resin-molding a molded object including a main body portion and a terminal having a flat surface extending from one end of the main body portion, wherein the molded object is installed so that a direction perpendicular to the direction in which the flat surface extends is perpendicular to the mold surface of the mold, and resin molding is performed. The mold is as follows: The mold includes an upper mold and a lower mold. One of the upper mold or the lower mold is as follows: It includes a cavity block in which a cavity for accommodating the main body portion is formed, and a terminal accommodating portion for accommodating the terminal. The terminal accommodating portion includes a terminal arrangement block and an elastic resin between the cavity block and the terminal arrangement block. The terminal accommodating portion is provided with a slit. A mold.

2. The elastic resin contains a fluororesin. The mold according to claim 1.

3. One of the molds is the lower mold. The mold according to claim 1.

4. The terminal arrangement block is configured to surround the elastic resin in a U-shape in a plan view. The mold according to claim 1.

5. The terminal accommodating portion further includes a pressing plate between the elastic resin and the terminal arrangement block. The pressing plate is movable in the direction in which the slit extends, and is configured to be able to press the elastic resin by moving the pressing plate. The mold according to claim 4.

6. A through hole penetrating the terminal arrangement block in the direction in which the slit extends is provided in the terminal arrangement block. The terminal accommodating portion further includes a pressing member configured to be movable in the direction in which the slit extends inside the through hole. The pressing member is configured to be able to press the pressing plate in the direction in which the slit extends. The mold according to claim 5.

7. The slit further includes a first slit provided in the cavity block, and the elastic resin is provided with a third slit narrower than the width of the first slit. The mold according to claim 1.

8. A resin molding apparatus including the mold according to any one of claims 1 to 7.

9. A resin molding system including the resin molding apparatus according to claim 8.

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