Injection Molding System

Abstract

To ensure a positioning accuracy of an insert component with respect to a mold.SOLUTION: An injection molding system includes: a first unit having a first injection molding machine that injects a first molding material into a first cavity defined by a first fixed mold and a movable mold; a second unit having a second injection molding machine that injects a second molding material into a second cavity defined by a second fixed mold and a movable mold; and a moving mechanism that moves the movable mold filled with the first molding material from the first injection molding machine to the second injection molding machine after the first molding material is injected toward the first cavity.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to injection molding systems. [Background technology]

[0002] Patent Document 1 discloses an injection molding system in which an insert part is placed in a mold and molten resin is injected into the mold to integrate the insert part and the resin. In this injection molding system, a holding member provided at the tip of a robot arm fits the insert part into a part holding portion provided in the mold, and the insert part is kept fitted in the part holding portion by being held by the holding member even after the operation to close the mold is started, and the holding member is retracted from between the molds before the closing of the molds is completed, thereby ensuring the positioning accuracy of the insert part relative to the mold. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-014049 Summary of the Invention [Problem to be solved by the invention]

[0004] The technique disclosed in the above document requires a complex configuration for ensuring the positioning accuracy of the insert part relative to the molding die. Therefore, there is a need for a technique that can easily ensure the positioning accuracy of the insert part relative to the molding die. [Means for solving the problem]

[0005] According to one aspect of the present disclosure, there is provided an injection molding system including: a first unit having a first injection molding machine that injects a first molding material into a first cavity defined by a first fixed mold and a movable mold, a second unit having a second injection molding machine that injects a second molding material into a second cavity defined by a second fixed mold and the movable mold, and a transfer mechanism that transfers the movable mold filled with the first molding material from the first injection molding machine to the second injection molding machine after the first molding material has been injected into the first cavity. [Brief explanation of the drawings]

[0006] [Figure 1] 1 is a front view showing a schematic configuration of an injection molding system according to a first embodiment. [Figure 2] 1 is a plan view showing a schematic configuration of an injection molding system according to a first embodiment. [Figure 3] FIG. 2 is an explanatory diagram showing a schematic configuration of a first injection device according to the first embodiment. [Figure 4] FIG. 2 is a perspective view showing a schematic configuration of a flat screw. [Figure 5] FIG. 2 is a plan view showing a schematic configuration of a barrel. [Figure 6] FIG. 2 is an explanatory diagram showing a schematic configuration of a second injection device according to the first embodiment. [Figure 7] FIG. 3 is a cross-sectional view showing the configuration of a second nozzle of the first embodiment. [Figure 8] FIG. 1 is a first explanatory diagram showing insert molding by an injection molding system. [Figure 9] FIG. 2 is a second explanatory diagram showing insert molding using an injection molding system. [Figure 10] FIG. 10 is an explanatory diagram showing a schematic configuration of a first injection molding machine according to a second embodiment. [Figure 11] FIG. 10 is an explanatory diagram showing a schematic configuration of a second injection molding machine according to a second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0007] A. First embodiment: FIG. 1 is a front view showing a schematic configuration of an injection molding system 10 according to a first embodiment. FIG. 2 is a plan view showing a schematic configuration of the injection molding system 10 according to the first embodiment. In FIGS. 1 and 2, arrows are shown along the mutually orthogonal X, Y, and Z directions. The X, Y, and Z directions are directions along the X, Y, and Z axes, which are three mutually orthogonal spatial axes. Each of the X, Y, and Z directions includes both a direction on one side of the X, Y, and Z axes and a direction opposite the X, Y, and Z axes. The X and Y axes are axes along a horizontal plane, and the Z axis is an axis along a vertical line. The -Z direction is the vertical direction, and the +Z direction is the direction opposite the vertical direction. The -Z direction is also referred to as "downward," and the +Z direction is also referred to as "upward." Arrows along the X, Y, and Z directions are also shown in other figures as appropriate. The X, Y, and Z directions in FIGS. 1 and 2 represent the same directions as those in other figures.

[0008] As shown in Fig. 1, the injection molding system 10 includes a first unit 100, a second unit 200, a third unit 300, and a fourth unit 400. In this embodiment, the first unit 100, the third unit 300, the second unit 200, and the fourth unit 400 are arranged in this order from the +Y direction to the -Y direction. As shown in Fig. 2, the injection molding system 10 further includes a control unit 500. In this embodiment, the control unit 500 is arranged in the +X direction relative to the first unit 100.

[0009] As shown in FIG. 1, in this embodiment, each of the units 100 to 400 has a box-shaped housing, and one or more devices, components, etc. are aggregated inside the housing to form a single unit. In the following description, the housing 101 of the first unit 100 may be referred to as the first housing 101, the housing 201 of the second unit 200 may be referred to as the second housing 201, the housing 301 of the third unit 300 may be referred to as the third housing 301, and the housing 401 of the fourth unit 400 may be referred to as the fourth housing 401. Each of the housings 101 to 401 is configured by a base and a cover that covers the top surface of the base. FIG. 2 shows each of the units 100 to 400 with the covers of the housings 101 to 401 removed. Note that in other embodiments, each of the units 100 to 400 may be configured as a single unit, for example, by aggregated one or more devices, components, etc. on a base.

[0010] As shown in FIG. 2 , in this embodiment, each of the units 100 to 400 is detachably connected to the adjacent unit. Specifically, a plate-like member 91 bridging the first unit 100 and the third unit 300 is fastened to both units 100 and 300 with bolts, thereby connecting the third unit 300 to the first unit 100. A plate-like member 91 bridging the third unit 300 and the second unit 200 is fastened to both units 200 and 300 with bolts, thereby connecting the second unit 200 to the third unit 300. A plate-like member 91 bridging the second unit 200 and the fourth unit 400 is fastened to both units 200 and 400 with bolts, thereby connecting the fourth unit 400 to the second unit 200. Note that the means for connecting the units 100 to 400 is not limited to means using the plate-like member 91 and bolts, and may be means using clamps, for example. Furthermore, the arrangement of each unit 100 to 400 can be freely changed by disconnecting it from adjacent units. For example, the first unit 100 and the second unit 200 may be arranged adjacent to each other. In this case, both units 100 and 200 may be detachably connected by a plate-like member 91 and a bolt.

[0011] As shown in Fig. 1, wheels 98 are attached to the bottom surface of the housings 101 to 401 of each of the units 100 to 400. When each of the units 100 to 400 is not connected to another unit, it can move independently using the wheels 98. A bolt-type stopper 99 is provided near each wheel 98. The stopper 99 allows each of the units 100 to 400 to be fixed in place.

[0012] As shown in FIG. 2 , the control unit 500 includes a control device 505. In this embodiment, the control device 505 is disposed inside a box-shaped electrical box 501. The control device 505 is connected to each of the units 100 to 400 via a cable 509. The control device 505 controls various devices provided in each of the units 100 to 400. In this embodiment, the control device 505 is configured by a PLC (programmable logic controller). The control device 505 controls the coordinated operations of the various devices provided in each of the units 100 to 400 by being programmed using a language such as ladder logic. Although not shown in the drawings, wheels 98 and stoppers 99 are also provided on the bottom surface of the electrical box 501, similar to the housings 101 to 401. The arrangement of the control unit 500 relative to each of the units 100 to 400 can be arbitrarily changed. For example, the control unit 500 may be disposed in the +Y direction relative to the first unit 100, instead of the +X direction relative to the first unit 100.

[0013] The first unit 100 includes a first injection molding machine 105. The first injection molding machine 105 is fixed to the first housing 101. The first injection molding machine 105 includes a first injection device 110 and a first mold clamping device 190. The first injection device 110 injects a first molding material. In this embodiment, the first molding material is, for example, a thermoplastic resin such as ABS resin or polypropylene (PP). The specific configuration of the first injection device 110 will be described later.

[0014] The first mold clamping unit 190 includes a first fixed platen 191, a first movable platen 192, a first tie bar 193, and a first mold drive unit 194. The first fixed platen 191 is fixed to the tip of a rod-shaped first tie bar 193. The first movable platen 192 moves along the first tie bar 193 by the first mold drive unit 194, which is configured by combining a motor, a reducer, and a ball screw.

[0015] A first fixed mold 21 is attached to the first fixed platen 191, and a movable mold 25 is attached to the first movable platen 192. The first fixed mold 21 is attached to the first fixed platen 191, for example, by bolts or a clamping device. The movable mold 25 is attached to the first movable platen 192, for example, by an electric clamping device driven under the control of the control device 505. The movable mold 25 moves together with the first movable platen 192 and comes into contact with the first fixed mold 21. A first cavity is formed when the movable mold 25 comes into contact with the first fixed mold 21. The first cavity is a space defined by the first fixed mold 21 and the movable mold 25. The first injection molding machine 105 injects a first molding material from a first injection device 110 toward the first cavity, thereby molding a first molded product made of the first molding material.

[0016] The second unit 200 includes a second injection molding machine 205. The second injection molding machine 205 is fixed to the second housing 201. The second injection molding machine 205 includes a second injection device 210 and a second mold clamping device 290. The second injection device 210 injects a second molding material. In this embodiment, the second molding material is a thermosetting resin. More specifically, in this embodiment, the second molding material is a two-component silicone rubber. The specific configuration of the second injection device 210 will be described later.

[0017] The second mold clamping unit 290 includes a second fixed platen 291, a second movable platen 292, second tie bars 293, and a second mold drive unit 294. The second fixed platen 291 is fixed to the tip of a rod-shaped second tie bar 293. The second movable platen 292 is moved along the second tie bar 293 by the second mold drive unit 294, which is configured by combining a motor, a reducer, and a ball screw.

[0018] The second fixed die 22 is attached to the second fixed platen 291, and the movable die 25 is attached to the second movable platen 292. The second fixed die 22 is attached to the second fixed platen 291, for example, by a bolt or a clamp device. The movable die 25 is attached to the second movable platen 292, for example, by an electric clamp device driven under the control of the control device 505. The movable die 25 moves together with the second movable platen 292 and comes into contact with the second fixed die 22. A second cavity is formed when the movable die 25 comes into contact with the second fixed die 22. The second cavity is a space defined by the second fixed die 22 and the movable die 25.

[0019] The second injection molding machine 205 injects the second molding material from the second injection device 210 toward the second cavity. After the first injection molding machine 105 has molded the first molded product, the movable mold 25 attached to the second movable platen 292 is transported from the first injection molding machine 105 to the second injection molding machine 205 by a moving mechanism 305 (described later). In this embodiment, the first molded product molded by the first injection molding machine 105 is in close contact with the movable mold 25 attached to the second injection molding machine 205 without being released. The second injection molding machine 205 molds a second molded product having a portion made of the first molding material and a portion made of the second molding material by insert molding using the first molded product as an insert part.

[0020] The third unit 300 includes a moving mechanism 305. The moving mechanism 305 is fixed to the third housing 301. The moving mechanism 305 moves the movable mold 25 from the first injection molding machine 105 to the second injection molding machine 205. In this embodiment, the moving mechanism 305 includes a first moving section 310, a second moving section 320, and a third moving section 330. The first moving section 310 is disposed in a portion of the third housing 301 near the first unit 100. The second moving section 320 is disposed in a central portion of the third housing 301. The third moving section 330 is disposed in a portion of the third housing 301 near the second unit 200.

[0021] The first mover 310 moves the movable mold 25 from the first injection molding machine 105 to the second mover 320. In this embodiment, the first mover 310 is configured by a robot arm. More specifically, in this embodiment, the first mover 310 is configured by a horizontal articulated robot. An end effector for gripping the movable mold 25 is attached to the tip of the first mover 310. In this embodiment, the end effector of the first mover 310 is a gripper that clamps and grips the movable mold 25. The first mover 310 is driven under the control of the control device 505. In this embodiment, a door or an opening is provided in a portion of the first housing 101 facing the third housing 301, and in a portion of the third housing 301 facing the first housing 101, thereby allowing the first mover 310 to access the inside of the first housing 101. After the first mover 310 grips the upper portion of the movable die 25, the clamp device provided on the first movable platen 192 releases the movable die 25 from its position. The first mover 310 pulls the movable die 25 upward from between the first fixed die 21 and the first movable platen 192. It is preferable that the movable die 25 be provided with a handle-like portion so that the end effector can easily grip the movable die 25. Note that in other embodiments, the first mover 310 may be configured by, for example, a vertical articulated robot instead of a horizontal articulated robot. The end effector of the first mover 310 may be a suction pad that vacuum-sucks the movable die 25 instead of a gripper.

[0022] The second moving unit 320 moves the movable mold 25 from the first moving unit 310 toward the third moving unit 330. In this embodiment, the second moving unit 320 includes a rail unit 321, a slide unit 322, and a slide drive unit 323. The rail unit 321 is provided along the Y direction. One end of the rail unit 321 is disposed near the first moving unit 310, and the other end of the rail unit 321 is disposed near the third moving unit 330. The slide unit 322 is configured to be movable on the rail unit 321 while being guided by the rail unit 321. The movable mold 25 is placed on the upper surface of the slide unit 322 by the first moving unit 310. The slide unit 322 is moved on the rail unit 321 by the slide drive unit 323. In this embodiment, the slide drive unit 323 is configured by combining a motor, a reducer, and a ball screw. The slide driving unit 323 is driven under the control of the control device 505 .

[0023] In this embodiment, the slide portion 322 is equipped with a temperature adjustment portion 325. The temperature adjustment portion 325 adjusts the temperature of the movable mold 25 disposed on the slide portion 322. In this embodiment, the temperature adjustment portion 325 is configured with a heater and heats the movable mold 25. The temperature adjustment portion 325 is connected to the control device 505 via, for example, a flexible cable, and the temperature of the temperature adjustment portion 325 is controlled by the control device 505. Note that in other embodiments, the temperature adjustment portion 325 may be configured to cool the movable mold 25. In this case, the temperature adjustment portion 325 may be configured with, for example, a pipe through which a refrigerant flows, or may be configured with a Peltier element. When the temperature adjustment portion 325 is configured with a pipe through which a refrigerant flows, the refrigerant can be supplied to the pipe via, for example, a flexible tube.

[0024] The third mover 330 moves the movable mold 25 from the second mover 320 to the second injection molding machine 205. In this embodiment, the third mover 330 is configured by a robot arm. More specifically, in this embodiment, the third mover 330 is configured by a horizontal articulated robot. An end effector for gripping the movable mold 25 is attached to the tip of the third mover 330. In this embodiment, the end effector of the third mover 330 is a gripper that clamps and grips the movable mold 25. The third mover 330 is driven under the control of the control device 505. In this embodiment, a door or an opening is provided in a portion of the second housing 201 facing the third housing 301 and in a portion of the third housing 301 facing the second housing 201, thereby allowing the third mover 330 to access the inside of the second housing 201. The third moving unit 330 inserts the movable mold 25 from above between the second fixed mold 22 and the second movable platen 292. The movable mold 25 is fixed to the second movable platen 292 by a clamp device provided on the second movable platen 292. Note that in other embodiments, the third moving unit 330 may be configured by, for example, a vertical articulated robot instead of a horizontal articulated robot. The end effector of the third moving unit 330 may be a suction pad that vacuum-sucks the movable mold 25 instead of a gripper.

[0025] In this embodiment, the fourth unit 400 includes a take-out device 405, an inspection device 406, and a stacking mechanism 407. The take-out device 405, the inspection device 406, and the stacking mechanism 407 are fixed to the fourth housing 401. The take-out device 405 takes out the second molded product from between the second fixed mold 22 and the movable mold 25. In this embodiment, the take-out device 405 is configured by a robot arm. More specifically, in this embodiment, the take-out device 405 is configured by a horizontal articulated robot. An end effector for gripping the second molded product is attached to the tip of the take-out device 405. The end effector of the take-out device 405 may be a gripper that clamps and grips the second molded product, or may be a suction pad that grips the second molded product by vacuum suction. A configuration for cutting the gate of the second molded product may be added to the end effector of the take-out device 405. For example, the end effector of the removal device 405 may be provided with a cutter for cutting the gate of the second molded product. In this embodiment, a door or an opening is provided in a portion of the second housing 201 facing the fourth housing 401, and in a portion of the fourth housing 401 facing the second housing 201, thereby enabling the removal device 405 to access the inside of the second housing 201. Note that the removal device 405 may be configured by, for example, a vertical articulated robot instead of a horizontal articulated robot.

[0026] The inspection device 406 inspects the second molded product. In this embodiment, the inspection device 406 is equipped with a camera for capturing an image of the second molded product, and performs an appearance inspection of the second molded product using the image obtained by capturing the image of the second molded product. A second molded product determined to be a non-defective product by the inspection device 406 is placed on a tray by the take-out device 405. A second molded product determined to be a defective product by the inspection device 406 is transported by the take-out device 405 to a predetermined defective product discharge area.

[0027] The stacking mechanism 407 stacks trays for storing second molded products that have been inspected by the inspection device 406. The stacking mechanism 407 includes a first lifting device 431 and a second lifting device 432. The take-out device 405 places the second molded products on a tray placed on the first lifting device 431. When a predetermined number of second molded products have been placed on the tray, the first lifting device 431 lowers the tray. The tray placed at the top of the second lifting device 432 is slid and placed on top of the lowered tray by the slide mechanism. Multiple trays are stacked on the second lifting device 432, and when the top tray moves onto the first lifting device 431, the second lifting device 432 raises the remaining trays. When a predetermined number of trays on which the second molded products have been placed are stacked on the first lifting device 431 in this way, the production of second molded products is temporarily paused. At this time, the worker can open the door provided on the fourth housing 401, remove the tray on which the second molded product is placed from the fourth housing 401, and replenish the second lifting device 432 with a new tray.

[0028] 3 is an explanatory diagram showing a schematic configuration of the first injection device 110. The first injection device 110 includes a plasticizing mechanism 120, a first injection control mechanism 170, and a first nozzle 180. The plasticizing mechanism 120 includes a screw case 121, a flat screw 130, a barrel 140, a heater 150, and a screw driver 160.

[0029] The screw case 121 and the barrel 140 are fixed to each other. The flat screw 130 is disposed in an internal space defined by the screw case 121 and the barrel 140. The flat screw 130 is driven to rotate about a rotation axis RX by a screw drive unit 160 configured by combining a motor and a reducer. A communication hole 149 communicating with a first injection cylinder 171 (described later) is provided in the center of the barrel 140. A heater 150 is provided near the communication hole 149.

[0030] The internal space in which the flat screw 130 is disposed is connected to the hopper 106 shown in FIG. 2 via a passage (not shown). The hopper 106 stores, for example, a pelletized first molding material. The first molding material supplied from the hopper 106 between the flat screw 130 and the barrel 140 is plasticized by the rotation of the flat screw 130 and heating by the heater 150. Plasticization, which encompasses melting, refers to the change from a solid to a fluid state. Specifically, for materials that undergo glass transition, plasticization refers to the temperature of the material rising above its glass transition point. For materials that do not undergo glass transition, plasticization refers to the temperature of the material rising above its melting point. The rotation of the flat screw 130 by the screw driver 160 and the heating by the heater 150 are controlled by a control device 505.

[0031] FIG. 4 is a perspective view showing a schematic configuration of the flat screw 130. The flat screw 130 has a substantially cylindrical shape. The height of the flat screw 130 in the axial direction, which is the direction along the central axis, is smaller than the diameter of the flat screw 130. A spiral groove 133 is formed on an end face 131 of the flat screw 130 facing the barrel 140, with the center at a central portion 132 of the end face 131. The groove 133 communicates with a material inlet 135 formed on the side face of the flat screw 130. The first molding material supplied from the hopper 106 is introduced into the groove 133 from the material inlet 135. In this embodiment, three grooves 133 are formed on the end face 131 of the flat screw 130. The grooves 133 are separated from each other by a ridge portion 134. The number of grooves 133 is not limited to three, and may be one, two, four or more. The shape of the groove 133 is not limited to a spiral shape, but may be a helical or involute curve shape, or may be a shape that describes an arc from the center portion 132 to the outer periphery.

[0032] FIG. 5 is a plan view showing a schematic configuration of the barrel 140. The barrel 140 has an opposing surface 141 that faces the end surface 131 of the flat screw 130. An opening of the aforementioned communication hole 149 is formed in the center of the opposing surface 141. The opposing surface 141 is formed with a plurality of guide grooves 145 that are connected to the communication hole 149 and extend spirally from the communication hole 149 toward the outer periphery. The first molding material supplied to the groove 133 of the flat screw 130 is plasticized between the flat screw 130 and the barrel 140 by the rotation of the flat screw 130 and heating by the heater 150. Then, the first molding material flows along the groove 133 and the guide groove 145 due to the rotation of the flat screw 130 and is guided to the central portion 132 of the flat screw 130. The material that has flowed into the central portion 132 is guided through the communication hole 149 to the first injection cylinder 171. The guide groove 145 does not have to be connected to the communication hole 149. Furthermore, the guide groove 145 does not have to be provided in the barrel 140.

[0033] As shown in FIG. 3 , the first injection control mechanism 170 includes a first injection cylinder 171, a first plunger 172, and a first plunger driver 173. The first injection control mechanism 170 has a function of injecting the first molding material in the first injection cylinder 171 into the first cavity via a first nozzle 180. The first injection control mechanism 170 controls the injection amount, injection speed, and injection pressure of the first molding material from the first nozzle 180 under the control of the control device 505. The first injection cylinder 171 is a substantially cylindrical member connected to the communication hole 149 of the barrel 140. The first plunger 172 is disposed within the first injection cylinder 171. The first plunger 172 slides inside the first injection cylinder 171 by a first plunger drive unit 173 configured by combining a motor and a reducer, and pressure-feeds the first molding material inside the first injection cylinder 171 to the first nozzle 180.

[0034] In this embodiment, the first nozzle 180 is configured as a hot runner nozzle. A heater is arranged around the first nozzle 180, and the control device 505 controls the heater to control the insulation temperature and injection temperature of the first molding material. The gate structure of the hot runner nozzle may be an open gate or a valve gate. Note that the first injection molding machine 105 may employ a cold runner instead of a hot runner.

[0035] 6 is an explanatory diagram showing a schematic configuration of the second injection device 210 in this embodiment. A first liquid supply device 220 and a second liquid supply device 230 are connected to the second injection device 210. In this embodiment, the first liquid supply device 220 and the second liquid supply device 230 are disposed in the second housing 201.

[0036] The first liquid supply device 220 includes a first tank 221 and a first pump 222. The first tank 221 stores the first liquid. The first liquid contains a base agent of a two-component second molding material. In this embodiment, the first liquid contains a silicone polymer as a base agent of two-component silicone rubber.

[0037] The first pump 222 is provided in the first tank 221. The first pump 222 pressure-feeds the first liquid stored in the first tank 221 to the second injection device 210. The first pump 222 is configured by, for example, a positive displacement pump such as a screw pump. The first pump 222 is driven under the control of the control device 505. The first pump 222 is connected to a flow path member 240 (described later) by a first pipe 223.

[0038] The second liquid supply device 230 includes a second tank 231 and a second pump 232. The second tank 231 stores the second liquid. The second tank 231 stores the second liquid. The second liquid contains a polymerization initiator that starts a polymerization reaction of the two-component second molding material. By combining a predetermined amount of the first liquid and a predetermined amount of the second liquid, the polymerization reaction of the two-component second molding material can be started.

[0039] The second pump 232 is provided in the second tank 231. The second pump 232 pressure-feeds the second liquid stored in the second tank 231 to the second injection device. The second pump 232 is configured by, for example, a positive displacement pump such as a screw pump. The second pump 232 is driven under the control of the control device 505. The second pump 232 is connected to the flow path member 240 by a second pipe 233.

[0040] The second injection device 210 includes a flow path member 240, a mixing section 250, a second injection control mechanism 270, and a second nozzle 280. In this embodiment, the flow path member 240 has a rectangular parallelepiped outer shape. A first pipe 223 and a second pipe 233 are connected to the flow path member 240. A first flow path 241, a second flow path 242, and a junction flow path 243 are provided inside the flow path member 240.

[0041] One end of the first flow path 241 is connected to the first pump 222 via the first pipe 223, and the other end of the first flow path 241 is connected to one end of the junction flow path 243. One end of the second flow path 242 is connected to the second pump 232 via the second pipe 233, and the other end of the second flow path 242 is connected to one end of the junction flow path 243. The first liquid that flows into the first flow path 241 from the first pipe 223 flows toward the junction flow path 243. The second liquid that flows into the second flow path 242 from the second pipe 233 flows toward the junction flow path 243. The first liquid and the second liquid join at the junction flow path 243 and flow to the mixing section 250.

[0042] The mixing section 250 includes a static mixer 251. The static mixer 251 includes a mixing cylinder 252 and an agitating member 253. The mixing cylinder 252 is a cylindrical member. One end of the mixing cylinder 252 is connected to the flow path member 240 via a first connecting member 255. The other end of the mixing cylinder 252 is connected to a side surface of a second injection cylinder 271 (described later) via a second connecting member 256. The mixing cylinder 252 communicates with the merging flow path 243 and the inside of the second injection cylinder 271.

[0043] The stirring member 253 is disposed within the mixing cylinder 252. In this embodiment, the stirring member 253 is composed of a plurality of mixing elements connected to one another. The plurality of mixing elements are arranged side by side from one end of the mixing cylinder 252 to the other. Each mixing element has a shape obtained by twisting a rectangular plate 180 degrees. The twist rotation directions of adjacent mixing elements are different from each other. Each mixing element is fixed to the inner wall surface of the mixing cylinder 252 and is stationary relative to the mixing cylinder 252. Note that, to facilitate understanding of the technology, FIG. 6 shows the stirring member 253 having four mixing elements, but the number of mixing elements of the stirring member 253 may be, for example, several or several tens.

[0044] The static mixer 251 mixes the first and second liquids that have flowed into the mixing cylinder 252 through the dividing, diverging, and reversing actions of each mixing element of the agitating member 253. The dividing action is the action of dividing the flow of fluid. The diverging action is the action of moving the fluid from the central axis of the mixing cylinder 252 toward the inner wall surface, or from the inner wall surface toward the central axis. The reversing action is the action of reversing the direction of the vortex of the fluid that flows in a vortex shape around the central axis of the mixing cylinder 252.

[0045] The second injection control mechanism 270 measures and injects the second molding material. In this embodiment, the second injection control mechanism 270 includes a second injection cylinder 271, a second plunger 272, and a second plunger driver 273.

[0046] The second injection cylinder 271 is a cylindrical member. A second molding material obtained by mixing the first liquid and the second liquid by the mixer 250 is stored inside the second injection cylinder 271. A second nozzle 280 is connected to the end of the second injection cylinder 271. A second plunger 272 is disposed inside the second injection cylinder 271.

[0047] The second plunger driving unit 273 moves the second plunger 272 along the central axis of the second injection cylinder 271. The second plunger driving unit 273 moves the second plunger 272 toward the second nozzle 280, thereby injecting the second molding material in the second injection cylinder 271 from the second nozzle 280. In this embodiment, the second plunger driving unit 273 is configured by combining a motor and a reducer. The second plunger driving unit 273 is driven under the control of the control device 505.

[0048] 7 is a cross-sectional view showing the configuration of the second nozzle 280. In this embodiment, the second nozzle 280 includes a nozzle tip 281, a nozzle flow path member 282, and a nozzle cover 283. The nozzle tip 281 is a cylindrical member. An opening for injecting the second molding material is provided at the tip of the nozzle tip 281. The rear end of the nozzle tip 281 is fixed to the second injection cylinder 271 via the nozzle flow path member 282.

[0049] The nozzle cover 283 is provided to cover the outer peripheral side surface of the nozzle tip 281 and the outer peripheral side surface of the nozzle flow path member 282. In this embodiment, a refrigerant inlet 285 and a refrigerant outlet 286 are provided on the side surface of the nozzle cover 283. A groove-shaped refrigerant flow path 287 that connects the refrigerant inlet 285 and the refrigerant outlet 286 is provided on the inner wall surface of the nozzle cover 283. A refrigerant RF is supplied to the refrigerant inlet 285. The refrigerant RF is, for example, water. The refrigerant RF introduced from the refrigerant inlet 285 to the refrigerant flow path 287 is discharged from the refrigerant outlet 286. The refrigerant RF discharged from the refrigerant outlet 286 is cooled, for example, by a chiller, and circulates to the refrigerant inlet 285. An O-ring 289 seals the gap between the nozzle cover 283 and the nozzle tip 281 and the gap between the nozzle cover 283 and the nozzle flow path member 282. The refrigerant flow path 287 may also be referred to as a cooling unit.

[0050] Fig. 8 is a first explanatory diagram showing the state of insert molding by the injection molding system 10. Fig. 9 is a second explanatory diagram showing the state of insert molding by the injection molding system 10. As shown in Fig. 8, first, in process P10, the movable mold 25 is mounted on the first injection molding machine 105. The movable mold 25 is inserted between the first fixed mold 21 and the first movable platen 192 by, for example, the first moving part 310, and fixed to the first movable platen 192 by a clamp device driven under the control of the control device 505.

[0051] In process P20, the first injection molding machine 105 brings the movable mold 25 into contact with the first fixed mold 21 using the first mold clamping unit 190, and then injects a first molding material MM1 from the first nozzle 180 of the first injection unit 110 toward the first cavity Cv1 defined by the first fixed mold 21 and the movable mold 25. The first molding material MM1 injected from the first nozzle 180 fills the first cavity Cv1. The first molding material MM1 hardens in the first cavity Cv1, thereby forming a first molded product MD1.

[0052] In step P30, the first injection molding machine 105 uses the first mold clamping device 190 to move the movable mold 25 away from the first fixed mold 21. In step P30, the ejector pins 29 housed in the movable mold 25 do not protrude from the movable mold 25 and do not release the first molded product MD1 from the movable mold 25. Thereafter, with the first molded product MD1 still in close contact with the movable mold 25, the movable mold 25 is removed from the first injection molding machine 105 by the first moving unit 310 of the moving mechanism 305 and moved to the second injection molding machine 205 by the second moving unit 320 and the third moving unit 330.

[0053] 9, in process P40, the moving mechanism 305 moves the movable mold 25 from the first injection molding machine 105 to the second injection molding machine 205, and the movable mold 25 is attached to the second injection molding machine 205. The first molded product MD1 is not released from the movable mold 25 attached to the second injection molding machine 205 and is in close contact with the movable mold 25. The movable mold 25 is inserted between the second fixed mold 22 and the second movable platen 292 by, for example, the third moving section 330, and is fixed to the second movable platen 292 by a clamping device driven under the control of the control device 505.

[0054] In process P50, the second injection molding machine 205 uses the second mold clamping unit 290 to bring the movable mold 25 into contact with the second fixed mold 22, and then injects a second molding material MM2 from the second nozzle 280 of the second injection unit 210 toward the second cavity Cv2 defined by the second fixed mold 22 and the movable mold 25. In this embodiment, a first molded product MD1 serving as an insert part is disposed in the second cavity Cv2, and therefore the second molding material MM2 injected from the second nozzle 280 fills the space defined by the second fixed mold 22, the movable mold 25, and the first molded product MD1. As the second molding material MM2 hardens in the space defined by the second fixed mold 22, the movable mold 25, and the first molded product MD1, a second molded product MD2 is formed in which a portion made of the first molding material MM1 and a portion made of the second molding material MM2 are integrated.

[0055] In step P60, the second injection molding machine 205 separates the movable mold 25 from the second fixed mold 22 using the second mold clamping device 290. In step P60, the ejector pins 29 housed in the movable mold 25 protrude from the movable mold 25, releasing the second molded product MD2 from the movable mold 25. The ejector pins 29 may be configured to protrude from the movable mold 25 in response to movement of the movable mold 25 relative to the second fixed mold 22, or may be configured to protrude from the movable mold 25 by a motor driven under the control of the control device 505, for example. The second molded products MD2 are then transported by the removal device 405 to the inspection device 406, where they are inspected and then arranged on a tray. The trays on which the second molded products MD2 are arranged are removed from the injection molding system 10. The movable mold 25 is removed from the second injection molding machine 205 by the third moving unit 330, and is moved to the first injection molding machine 105 by the second moving unit 320 and the first moving unit 310. The injection molding system 10 can repeatedly manufacture the second molded product MD2 by the above-mentioned method.

[0056] According to the injection molding system 10 of the present embodiment described above, after the first injection molding machine 105 molds the first molded product MD1 using the first fixed mold 21 and the movable mold 25, the movement mechanism 305 moves the movable mold 25, with the first molded product MD1 still in close contact with it, from the first injection molding machine 105 to the second injection molding machine 205, and the second injection molding machine 205 molds the second molded product MD2 using the second fixed mold 22 and the movable mold 25, with the first molded product MD1 as an insert part. Prior to molding the second molded product MD2, the first molded product MD1, which is the insert part, is not released from the movable mold 25, thereby suppressing misalignment of the insert part relative to the movable mold 25. Therefore, during insert molding, it is easy to ensure the positioning accuracy of the insert part relative to the movable mold 25.

[0057] Furthermore, in this embodiment, the moving mechanism 305 is configured so that the first moving unit 310 moves the movable mold 25 from the first injection molding machine 105 to the second moving unit 320, the second moving unit 320 moves the movable mold 25 from the vicinity of the first moving unit 310 to the vicinity of the third moving unit 330, and the third moving unit 330 moves the movable mold 25 from the second moving unit 320 to the second injection molding machine 205. This makes it possible to prevent the configurations and operations of the moving units 310 to 330 from becoming complicated.

[0058] Furthermore, in this embodiment, the second moving part 320 is provided with a temperature adjusting part 325 for adjusting the temperature of the movable mold 25 at the slide part 322 on which the movable mold 25 is placed. Therefore, the movable mold 25 can be kept warm or preheated while the movable mold 25 is being moved by the second moving part 320 or while the movable mold 25 is waiting on the slide part 322. In particular, in this embodiment, since the second molding material MM2 injected by the second injection molding machine 205 is a thermosetting resin, the time required for hardening the second molding material MM2 can be shortened by keeping the movable mold 25 warm or preheating it.

[0059] In this embodiment, the moving mechanism 305 is provided in the third unit 300, which is disposed between the first unit 100 having the first injection molding machine 105 and the second unit 200 having the second injection molding machine 205. Therefore, the injection molding system 10 can be made smaller in size in the front-to-rear direction compared to a configuration in which the moving mechanism 305 is provided in front of or behind the first unit 100 and the second unit 200. Furthermore, by providing the moving mechanism 305 in the third unit 300, the installation location of the moving mechanism 305 can be easily changed.

[0060] In this embodiment, the movable die 25 is provided with an ejector pin 29 that pushes out the second molded product MD2. Therefore, the second molded product MD2 can be easily released from the movable die 25.

[0061] In this embodiment, the first molding material MM1 injected by the first injection molding machine 105 is a thermoplastic resin, and the second molding material MM2 injected by the second injection molding machine 205 is a thermosetting resin. Therefore, it is possible to mold a second molded product MD2 in which a portion made of thermoplastic resin and a portion made of thermosetting resin are integrated.

[0062] Furthermore, in this embodiment, the second injection molding machine 205 that injects the thermosetting resin is provided with a refrigerant flow path 287 for cooling the second nozzle 280. Therefore, it is possible to prevent the thermosetting resin from starting to harden inside the second nozzle 280 and causing clogging of the second nozzle 280.

[0063] B. Second embodiment: Figure 10 is an explanatory diagram showing a schematic configuration of a first injection molding machine 105b in the second embodiment. Figure 11 is an explanatory diagram showing a schematic configuration of a second injection molding machine 205b in the second embodiment. The second embodiment differs from the first embodiment in that the first injection molding machine 105b is equipped with a plurality of first nozzles 180 and the second injection molding machine 205b is equipped with a plurality of second nozzles 280. The other configurations are the same as those in the first embodiment unless otherwise specified.

[0064] As shown in FIG. 10 , in this embodiment, a plurality of first cavities Cv1 are defined by the first fixed mold 21b and the movable mold 25b. The first fixed mold 21b has a plurality of first openings 23. Each first opening 23 is connected to a corresponding first cavity Cv1. FIG. 10 shows two first nozzles 180, two first openings 23, and four first cavities Cv1. One of the two first openings 23 is connected to two first cavities Cv1. The other of the two first openings 23 is connected to two first cavities Cv1 different from the two first cavities Cv1 described above. Each first nozzle 180 is connected to a first injection cylinder 171. The first molding material injected from one of the two first nozzles 180 fills the two first cavities Cv1 through one of the two first openings 23. The first molding material injected from the other of the two first nozzles 180 fills two first cavities Cv1 different from the two first cavities Cv1 described above through the other of the two first openings 23.

[0065] As shown in FIG. 11, in this embodiment, a plurality of second cavities Cv2 are defined by the second fixed mold 22b and the movable mold 25b. The number of second cavities Cv2 is the same as the number of first cavities Cv1. The position of each second cavity Cv2 corresponds to the position of each first cavity Cv1. The second fixed mold 22b has a plurality of second openings 24. Each second opening 24 is connected to a corresponding second cavity Cv2. FIG. 11 shows two second nozzles 280, two second openings 24, and four second cavities Cv2. One of the two second openings 24 is connected to two second cavities Cv2. The other of the two second openings 24 is connected to two second cavities Cv2 different from the two second cavities Cv2 described above. Each second nozzle 280 is connected to a second injection cylinder 271. The second molding material injected from one of the two second nozzles 280 is filled into two second cavities Cv2 through one of the two second openings 24. The second molding material injected from the other of the two second nozzles 280 is filled into two second cavities Cv2 different from the two second cavities Cv2 described above through the other of the two second openings 24. A first molded product MD1 is disposed in each second cavity Cv2 into which the second molding material is filled, and a second molded product MD2 is molded in each second cavity Cv2, in which a portion made of the first molding material MM1 and a portion made of the second molding material MM2 are integrated.

[0066] According to the present embodiment described above, a large number of second molded products MD2 using first molded products MD1 as insert parts can be molded at once. Conventionally, when insert parts are installed in cavities manually or by a robot arm, the greater the number of cavities, the more time and effort it takes to install the insert parts. In contrast, in this embodiment, installing the insert parts does not require much time or effort. Therefore, the second molded products MD2 can be molded efficiently.

[0067] C. Other Embodiments: (C1) In each of the above-described embodiments, the first injection molding machine 105, 105b is configured to inject a thermoplastic resin as the first molding material MM1, and the second injection molding machine 205, 205b is configured to inject a thermosetting resin as the second molding material MM2. Alternatively, the first injection molding machine 105, 105b may be configured to inject a thermoplastic resin as the first molding material MM1, and the second injection molding machine 205, 205b may be configured to inject a thermoplastic resin as the second molding material MM2. Alternatively, the first injection molding machine 105, 105b may be configured to inject a thermosetting resin as the first molding material MM1, and the second injection molding machine 205, 205b may be configured to inject a thermosetting resin as the second molding material MM2. Alternatively, the first injection molding machine 105, 105b may be configured to inject a thermosetting resin as the first molding material MM1, and the second injection molding machine 205, 205b may be configured to inject a thermoplastic resin as the second molding material MM2.

[0068] (C2) In each of the above-described embodiments, the moving mechanism 305 is provided in the third unit 300. However, the moving mechanism 305 does not have to be integrated into one unit. For example, the moving mechanism 305 may be configured by a robot arm provided in the first unit 100 having the first injection molding machine 105 and a robot arm provided in the second unit 200 having the second injection molding machine 205.

[0069] (C3) In each of the above-described embodiments, the moving mechanism 305 is made up of three moving units 310 to 330. In contrast to this, the moving mechanism 305 may be made up of one robot arm that moves the movable mold 25 from the first injection molding machine 105 to the second injection molding machine 205, or the moving mechanism 305 may be made up of the first moving unit 310 and the third moving unit 330.

[0070] (C4) In each of the above-described embodiments, the moving mechanism 305 moves the movable mold 25 from the first injection molding machine 105 to the second injection molding machine 205 via a path that passes over the base of the housing. Alternatively, a passage for the movable mold 25 may be provided inside the base of the housing, and the moving mechanism 305 may be configured to move the movable mold 25 from the first injection molding machine 105 to the second injection molding machine 205 via a path that passes through this passage. The moving mechanism 305 may be configured to move the movable mold 25 from the first injection molding machine 105 to the second injection molding machine 205 via a path that passes through the front or rear outside the housing.

[0071] (C5) In each of the above-described embodiments, the temperature adjustment unit 325 is provided on the sliding portion 322 of the second moving portion 320. However, the temperature adjustment unit 325 does not necessarily have to be provided.

[0072] (C6) In each of the above-described embodiments, the movable molds 25, 25b are provided with the ejector pins 29. However, the movable molds 25, 25b do not necessarily have to be provided with the ejector pins 29.

[0073] (C7) In each of the above-described embodiments, the second nozzle 280 that injects the thermosetting resin is provided with the coolant flow path 287. However, the second nozzle 280 does not necessarily have to be provided with the coolant flow path 287.

[0074] (C8) In each of the above-described embodiments, after the first injection molding machine 105 injects the first molding material MM1 toward the first cavity Cv1, the movement mechanism 305 moves the movable mold 25 filled with the first molding material MM1 from the first injection molding machine 105 to the second injection molding machine 205, and the second injection molding machine 205 injects the second molding material MM2 toward the second cavity Cv2. Alternatively, while the movable mold 25 is being moved from the first injection molding machine 105 to the second injection molding machine 205, or while the second injection molding machine 205 is injecting the second molding material MM2 toward the second cavity Cv2, the first injection molding machine 105 may inject the first molding material MM1 into another movable mold 25. In this case, the molded products MD1 and MD2 can be molded more efficiently.

[0075] D. Other forms: The present disclosure is not limited to the above-described embodiments and can be realized in various forms without departing from the spirit thereof. For example, the present disclosure can also be realized in the following forms. The technical features in the above embodiments corresponding to the technical features in each form described below can be appropriately replaced or combined to solve some or all of the problems of the present disclosure or to achieve some or all of the effects of the present disclosure. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted.

[0076] (1) According to one aspect of the present disclosure, there is provided an injection molding system including: a first unit having a first injection molding machine that injects a first molding material into a first cavity defined by a first fixed mold and a movable mold, a second unit having a second injection molding machine that injects a second molding material into a second cavity defined by a second fixed mold and the movable mold, and a transfer mechanism that transfers the movable mold filled with the first molding material from the first injection molding machine to the second injection molding machine after the first molding material has been injected into the first cavity. In this injection molding system, the moving mechanism moves the movable mold to the second injection molding machine, with the insert part made of the first molding material molded by the first injection molding machine in close contact with it, eliminating the need to position the insert part prior to the injection of the second molding material from the second injection molding machine, thereby facilitating the positioning of the insert part.

[0077] (2) In the injection molding system of the above form, the moving mechanism may include a first moving unit that removes the movable mold from the first injection molding machine, a second moving unit that moves the movable mold removed by the first moving unit from the first unit toward the second unit, and a third moving unit that places the movable mold moved by the second moving unit on the second injection molding machine. According to the injection molding system of this form, it is possible to prevent the operations of each moving part from becoming complicated.

[0078] (3) In the injection molding system of the above aspect, the moving mechanism may include a temperature adjusting unit that adjusts the temperature of the movable mold when the movable mold is moved from the first injection molding machine to the second injection molding machine. This type of injection molding system allows for temperature control of the moving mold during movement.

[0079] (4) The injection molding system of the above aspect may include a third unit disposed between the first unit and the second unit, and the movement mechanism may be provided in the third unit. According to this type of injection molding system, the moving mechanism is integrated into one unit, so when the installation location of the moving mechanism needs to be changed, the installation location of the moving mechanism can be easily changed.

[0080] (5) In the injection molding system of the above aspect, the movable mold may include an ejector pin that pushes out the molded product. According to the injection molding system of this aspect, the molded product having a portion made of the first molding material and a portion made of the second molding material can be easily removed from the movable mold.

[0081] (6) In the injection molding system of the above aspect, at least one of the first molding material and the second molding material may be a thermosetting resin. According to this type of injection molding system, it is possible to mold a molded article at least partly made of a thermosetting resin.

[0082] (7) In the injection molding system of the above aspect, at least one of the first injection molding machine and the second injection molding machine may include a nozzle that injects the thermosetting resin and a cooling unit that cools the nozzle. According to this type of injection molding system, the nozzle that injects the thermosetting resin can be cooled by the cooling section, so that the thermosetting resin can be prevented from hardening inside the nozzle.

[0083] (8) In the injection molding system of the above form, the first fixed mold and the movable mold may define a plurality of the first cavities, the second fixed mold and the movable mold may define a plurality of the second cavities, the first fixed mold may have a plurality of first openings communicating with the plurality of the first cavities, the second fixed mold may have a plurality of second openings communicating with the plurality of the second cavities, the first injection molding machine may have a plurality of first nozzles that inject the first molding material into the plurality of first openings, and the second injection molding machine may have a plurality of second nozzles that inject the second molding material into the plurality of second openings. According to the injection molding system of this form, it is possible to mold a plurality of molded articles, each having a portion made of the first molding material and a portion made of the second molding material, at one time.

[0084] The present disclosure may be realized in various forms other than an injection molding system, such as a control method for an injection control system or an insert molding method. [Explanation of symbols]

[0085] 10...injection molding system, 21...first fixed mold, 22...second fixed mold, 25...movable mold, 29...ejector pin, 100...first unit, 101...first housing, 105...first injection molding machine, 110...first injection unit, 180...first nozzle, 190...first mold clamping unit, 200...second unit, 201...second housing, 205...second injection molding machine, 210...second injection unit, 280...second nozzle, 287...refrigerant flow path, 290...second mold clamping unit Apparatus, 300...third unit, 301...third housing, 305...moving mechanism, 310...first moving section, 320...second moving section, 321...rail section, 322...slide section, 323...slide driving section, 325...temperature adjusting section, 330...third moving section, 400...fourth unit, 401...fourth housing, 405...removal device, 406...inspection device, 407...stacking mechanism, 500...control unit, 501...electrical box, 505...control device

Claims

1. a first unit having a first injection molding machine that injects a first molding material into a first cavity defined by a first fixed mold and a movable mold; a second unit having a second injection molding machine that injects a second molding material toward a second cavity defined by a second fixed mold and the movable mold; a moving mechanism that moves the movable mold filled with the first molding material from the first injection molding machine to the second injection molding machine after the first molding material has been injected into the first cavity; Equipped with the moving mechanism includes a first moving unit, a second moving unit, and a third moving unit; the first moving unit moves the movable mold from the first injection molding machine to the second moving unit; the second moving unit linearly moves the movable mold after the movement by the first moving unit along a direction from the first unit toward the second unit, the third moving unit moves the movable mold, after being moved by the second moving unit, from the second moving unit to the second injection molding machine. Injection molding system.

2. 10. The injection molding system of claim 1, An injection molding system, wherein the moving mechanism includes a temperature adjusting unit that adjusts the temperature of the movable mold when the movable mold is moved from the first injection molding machine to the second injection molding machine.

3. 3. The injection molding system according to claim 1 or claim 2, a third unit disposed between the first unit and the second unit; The moving mechanism is provided in the third unit.

4. 4. An injection molding system according to any one of claims 1 to 3, An injection molding system, wherein the movable mold is provided with an ejector pin that ejects the molded product.

5. 5. An injection molding system according to any one of claims 1 to 4, At least one of the first mold material and the second mold material is a thermosetting resin.

6. 6. The injection molding system of claim 5, an injection molding system, wherein at least one of the first injection molding machine and the second injection molding machine includes a nozzle that injects the thermosetting resin and a cooling unit that cools the nozzle.

7. The injection molding system of claim 2, the second moving portion includes a slide portion and a rail portion, An injection molding system in which the movable mold is placed on the upper surface of the slide portion by the first moving portion, and the movable mold moves as the slide portion moves on the rail portion.

8. The injection molding system of claim 7, An injection molding system, wherein the temperature adjustment unit is disposed on the slide unit and adjusts the temperature of the movable mold while the movable mold is being moved by the second moving unit.

9. A first unit having a first injection molding machine that injects a first molding material into a first cavity defined by a first fixed mold and a movable mold; a second unit having a second injection molding machine that injects a second molding material toward a second cavity defined by a second fixed mold and the movable mold; a moving mechanism that moves the movable mold filled with the first molding material from the first injection molding machine to the second injection molding machine after the first molding material has been injected into the first cavity; Equipped with the first fixed mold and the movable mold define a plurality of the first cavities; the second fixed mold and the movable mold define a plurality of the second cavities; the first fixed mold has a plurality of first openings communicating with the plurality of first cavities, the second fixed mold has a plurality of second openings communicating with the plurality of second cavities, the first injection molding machine includes a plurality of first nozzles configured to inject the first molding material into the plurality of first openings; An injection molding system, wherein the second injection molding machine is equipped with a plurality of second nozzles that inject the second molding material into the plurality of second openings.

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