CN111331778A - Method and apparatus for molding composite of insert and resin material - Google Patents

Abstract

The present invention provides a method for molding a composite of an insert and a resin material, and an apparatus for forming a composite of an insert and a resin material, which can cope with molding with various variations including molding to attach resin to both sides of the insert. The opened first metal mold (14) and the intermediate metal mold (18) are closed, and the resin material (M1) is injected into the cavity (C1) formed by the above-mentioned mold closing to form a primary molded product (P1). , rotate and move the intermediate metal mold holding the primary molded product (P1) toward a position facing the second metal mold, until the intermediate metal mold and the second metal mold are closed to form the primary molded product (P1) in any step up to the cavity (C2), inserting into at least one of the first metal mold (14), the intermediate metal mold (18), the second metal mold (16), and the primary molded product (P1) The insert (I) injects the resin material (M2) into the above-mentioned chamber (C2).

Description

Forming method and forming apparatus of composite body of insert and resin material

technical field

The present invention relates to a method for molding a composite body of an insert and a resin material, and a molding device for a composite body of an insert and a resin material.

Background technique

The use of resin materials such as reinforced fiber resin materials has been increasing in fields such as weight reduction of automobiles. However, in addition to the problem of strength, molded articles made of resin materials such as reinforcing fiber materials also have problems of bonding with other components, problems of molding accuracy, etc. Development of the complex is ongoing. In Patent Document 1, in addition to a method for forming a composite of a metal material and a reinforcing fiber resin material by thermocompression bonding, FIG. 7 describes a method for forming a composite of a metal material and a reinforcing fiber resin material by injection molding. .

In addition, Patent Document 2 describes a method for forming a composite of a metal material and a reinforced fiber resin material by injection-molding a surface layer and then injection-molding a core with an extrusion pin serving as an insert inserted into a cavity Floor. In addition, Patent Document 2 also describes the content of a cylindrical insert that is inserted into a metal cylinder after a part of the surface layer is removed from the molded product.

prior art literature

Patent Literature

Patent Document 1: Japanese Patent Application Laid-Open No. 2016-55539 (claim 3, paragraph 0047, FIG. 7 )

Patent Document 2: Japanese Patent Application Laid-Open No. 10-24447 (claim 1, paragraphs 0012 and 0013, FIG. 3 )

SUMMARY OF THE INVENTION

The problem to be solved by the invention

These molding methods using the composite body of the insert and the resin material by injection molding allow the insert and the resin material to be joined together with the injection molding of the resin, and are therefore excellent in productivity compared to other molding methods in many cases. However, the method of forming the composite body of the insert and the resin material of Patent Document 1 and Patent Document 2 has a problem that it is difficult to cope with various forming methods as described below.

Specifically, in the molding methods of Patent Document 1 and Patent Document 2, since the insert made of a metal material to be inserted is brought into contact with the metal mold, the reinforcing fiber resin material can be attached to only one side of the insert, and there is a problem that it is difficult to form the insert on the insert. The problem of all-around adhesion of reinforced fiber resin material. In addition, since insert molding and injection molding are generally performed using a single metal mold, there is a problem that there is a problem in that the injection molding of resin materials with different types and properties is restricted in molding. Furthermore, since a single metal mold is generally used, it is difficult to apply various moldings such as further processing, coating, or preheating to parts of the insert made of metal materials, reinforcing fibers, and the like. Moreover, if these moldings with variations are performed on a single metal mold, the molding cycle will be prolonged.

In view of the above problems, an object of the present invention is to provide a method for molding a composite body of an insert and a resin material, and an apparatus for forming a composite body of an insert and a resin material, which can correspond to molding including resin adhering to both sides of the insert. The formation of a change.

solutions to problems

The method for forming a composite body of an insert and a resin material according to claim 1 of the present invention is a method for forming a composite body of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, and is characterized in that: It is to use an injection molding machine which is rotatably arranged around an axis perpendicular to the mold opening direction between the first plate on which the first metal mold is mounted and the second plate on which the second metal mold is mounted. An intermediate member to which an intermediate mold is attached is provided, the opened first mold and the intermediate mold are closed, and a resin material is injected into the cavity formed by the above-mentioned mold closing to form a primary molded product, and the above-mentioned mold is retained. The intermediate mold of the primary molded product is rotationally moved to a position opposed to the second mold, and any process until the intermediate mold and the second mold are closed to form a cavity containing the primary molded product In the process, an insert is inserted into at least one of the first mold, the intermediate mold, the second mold, and the primary molded product, and the resin material is injected into the cavity containing the primary molded product.

The method for forming a composite body of an insert and a resin material according to claim 2 of the present invention is a method for forming a composite body of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, and is characterized in that: It is to use an injection molding machine which is rotatably arranged around an axis perpendicular to the mold opening direction between the first plate on which the first metal mold is mounted and the second plate on which the second metal mold is mounted. An intermediate member to which an intermediate metal mold is attached is provided, an insert is inserted into the opened first metal mold or the intermediate metal mold facing the first metal mold, the first metal mold and the intermediate metal mold are closed, and the inserts are The cavity on the side where the insert is inserted is injected with a resin material to mold a primary molded product composed of the insert and the resin material, and the first die and the primary die are held in the state of the intermediate die. The intermediate metal mold is opened, the intermediate metal mold holding the primary molded product is rotated and moved to a position facing the second metal mold, the intermediate metal mold and the second metal mold are closed, and the intermediate metal mold is closed by the mold closing. The cavity on the other side of the insert containing the primary molded product is formed to inject resin material.

The method for molding a composite body of an insert and a resin material according to claim 3 of the present invention is a method for molding a composite body of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, and is characterized in that: It is to use an injection molding machine which is rotatably arranged around an axis perpendicular to the mold opening direction between the first plate on which the first metal mold is mounted and the second plate on which the second metal mold is mounted. The intermediate member to which the intermediate mold is attached is provided, the first mold and the intermediate mold are closed, the resin material is injected into the cavity between the first mold and the intermediate mold, and the primary molded product made of the resin material is held. In the state of the intermediate metal mold, the first metal mold and the intermediate metal mold are opened, and the intermediate member and the intermediate metal mold holding the above-mentioned primary molded product are rotated and moved toward the position opposite to the second metal mold, until the above-mentioned During the period until the intermediate mold and the second mold are closed, a second insert is inserted into at least one of the primary molded product, the intermediate mold, and the second mold, and the primary molded product formed by the mold closing includes the primary molded product. And the cavity of the second insert is injected with resin material.

The method for molding a composite body of an insert and a resin material according to claim 4 of the present invention is a method for molding a composite body of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, and is characterized in that: It is to use an injection molding machine which is rotatably arranged around an axis perpendicular to the mold opening direction between the first plate on which the first metal mold is mounted and the second plate on which the second metal mold is mounted. An intermediate member on which an intermediate metal mold is installed is provided, the first insert is inserted into the opened first metal mold or the intermediate metal mold facing the first metal mold, and the first metal mold and the intermediate metal mold are closed. A resin material is injected into the cavity containing the inserted first insert to mold a primary molded product composed of the insert and the resin material, and the first metal molded product is held in a state of the intermediate mold. The mold and the intermediate mold are opened, and the intermediate mold holding the primary molded product is rotationally moved to a position opposed to the second mold. During the period until the intermediate mold and the second mold are closed, The second insert is inserted into at least one of the primary molded product, the intermediate metal mold, and the second metal mold, and the resin material is injected into the cavity formed by the above-mentioned closed mold and containing the primary molded product and the second insert.

The method for forming a composite body of an insert and a resin material according to claim 5 of the present invention is a method for forming a composite body of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, and is characterized in that: It is to use an injection molding machine which is rotatably arranged around an axis perpendicular to the mold opening direction between the first plate on which the first metal mold is mounted and the second plate on which the second metal mold is mounted. An intermediate member on which an intermediate metal mold is attached is provided, and an insert is inserted into the opened first metal mold or the intermediate metal mold facing the first metal mold, and the first metal mold is kept in the opened state or the first metal mold and the first metal mold are inserted. After the intermediate metal mold is closed, additional processing is performed on the above-mentioned insert, and the resin material is injected into the cavity containing the additionally processed insert to form a primary molded product composed of the insert and the resin material. In the state where the above-mentioned primary molded product is held by the intermediate metal mold, the first metal mold and the intermediate metal mold are opened, and the intermediate metal mold holding the above-mentioned primary molded product is rotated and moved toward the position facing the second metal mold, and the second metal mold is moved. The intermediate mold and the second mold are closed, and a resin material is injected into the cavity formed by the closed mold and containing the primary molded product.

A sixth aspect of the present invention is the method for forming a composite of an insert and a resin material according to any one of the first to fifth aspects, wherein the insert is a metal material or a material containing reinforcing fibers.

The apparatus for forming a composite body of an insert and a resin material according to claim 7 of the present invention is characterized by including a metal including a metal used for the method for forming the composite body of an insert and a resin material according to any one of claims 1 to 6. An injection molding machine for a mold; and a robot that is arranged on the side of the injection molding machine and inserts an insert into a predetermined position of a metal mold or a primary molded product.

effect of invention

The method for molding a composite of an insert and a resin material according to the present invention is a method of molding a composite of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, wherein an injection molding machine is used, In this injection molding machine, between a first disk on which a first mold is mounted and a second disk on which a second mold is mounted, an intermediate mold mounted rotatable centering on an axis perpendicular to the mold opening direction is arranged. An intermediate member, which closes the opened first mold and the intermediate mold, injects a resin material into the cavity formed by the mold closing, molds a primary molded product, and holds the intermediate mold for the primary molded product Rotate and move toward the position facing the second metal mold, and in any process until the intermediate metal mold and the second metal mold are closed to form a cavity containing the primary molded product, the first metal mold, the intermediate metal mold At least one insert of the metal mold, the second metal mold, and the primary molded product injects the resin material into the cavity containing the primary molded product, so that the composite body of the insert and the resin material with various variations can be molded .

Description of drawings

FIG. 1 is a plan view of an injection molding machine according to the present embodiment of the present invention, and is a plan view showing a state at the time of mold opening.

2 is a plan view of the injection molding machine according to the present embodiment of the present invention, and is a plan view showing a state when the mold is closed.

3 is an explanatory diagram showing a molding method according to the first embodiment of the present invention.

FIG. 4 is an explanatory diagram showing a molding method according to a second embodiment of the present invention.

5 is an explanatory diagram showing a molding method according to a third embodiment of the present invention.

6 is an explanatory diagram showing a molding method according to a fourth embodiment of the present invention.

FIG. 7 is a front view of a composite body of the insert I and the resin material M molded by the molding method according to the first embodiment of the present invention.

FIG. 8 is a cross section taken along line BB of FIG. 7 .

In the picture:

11—injection molding machine, 13—clamping device, 14—movable metal mold, 15—movable disk, 16—fixed metal mold, 17—fixed disk, 18—intermediate metal mold, 25—intermediate part (rotating disk) , 49—the first injection device, 50—the second injection device, C0, C1, C2—chambers, I, Ia, Ib—inserts, M1, M2—resin materials, P1—one-time moldings, P2—inserts Composite with resin material (finished product).

Detailed ways

An injection molding machine 11 according to an embodiment of the present invention will be described with reference to FIGS. 1 and 2 . The injection molding machine 11 is an injection molding machine 11 for molding a composite body of the insert I and the resin materials M1 and M2. A mold clamping device 13 is arranged on the upper surface of the bed body 12 . The mold clamping device 13 is arranged such that the rotary disk 25 as the intermediate member on which the intermediate mold 18 is mounted is placed between the movable disk 15 as the first disk on which the movable mold 14 as the first mold is mounted and the movable disk 15 as the first disk on which the movable mold 14 as the first mold is mounted. The fixed plate 17 serving as the second plate of the fixed metal mold 16 of the second metal mold is movable in the mold opening and closing direction AA and is rotatable about an axis O orthogonal to the mold opening direction. Furthermore, the fixed metal mold 16 and the intermediate metal mold 18, the movable metal mold 14 and the intermediate metal mold 18 are closed by mold opening and closing units 19 and 20, respectively, to form the first cavity C1 and the second cavity C2, respectively. , and the mold is closed by the clamping unit 21 .

A mold clamping cylinder 22 of the mold clamping unit 21 is provided near the four corners of the above-mentioned fixed plate 17 , and the connecting rod of the mold clamping cylinder 22 is a tie rod 23 . Furthermore, a movable platen 15 which is movable in the mold opening and closing direction AA with respect to the fixed platen 17 is inserted through the tie rod 23 , and a movable platen 15 which is located between the fixed platen 17 and the movable platen 15 and is movable in the mold opening and closing direction AA The moving upper frame (not shown) and the lower frame 24 . Between the upper frame inserted through the two tie rods 23 on the upper side and the lower frame 24 inserted through the two tie rods 23 on the lower side, it is rotatably arranged around an axis orthogonal to the mold opening and closing direction AA. A rotary disk 25 is provided as an intermediate member. Further, the intermediate molds 18 are attached to the mold mounting surfaces on both sides of the rotary disk 25, respectively. The intermediate mold 18 is provided with an improvement or device for maintaining the shape of the primary molded product P1 when it is released from the mold.

In addition, in the above, the lower frame 24 may also be supported on the bed body 12 . In addition, the upper frame may also be omitted. Furthermore, the upper frame and the lower frame 24 may be omitted, and the movable member not guided by the tie rod 23 may be provided on the bed body 12 so as to be movable in the mold opening/closing direction AA, and the rotating member rotatable relative to the above-mentioned movable frame may be erected. A disk (intermediate member), and an intermediate mold is attached to the mold mounting surfaces on both sides of the rotary disk, respectively. In addition, the upper surface of the rotatable rotary table on the upper surface of the movable member may be attached to one intermediate metal mold having cavity surfaces on both sides or four sides. In this case, the rotary table corresponds to the intermediate member. Furthermore, between the upper frame and the lower frame 24 and on both sides of the part of the intermediate member, one intermediate die to which the die part is attached may be rotatably attached. In each example of the present invention, the term "rotatably providing the intermediate member" means that in addition to repeated intermittent rotation in one direction, forward rotation and reverse rotation are included at angles such as 180°.

The clamping cylinder 22 is hydraulically actuated, and hydraulic oil is supplied to the clamping side oil chamber 29a or the mold opening side oil chamber 29b of the clamping cylinder 22 from a pump 27 provided connected to the tank 26 via a switching valve 28 . In addition, the mold clamping unit is not limited to the mold clamping cylinder 22 of FIG. 1 . Moreover, the movable metal mold|die 14 is attached to the movable platen 15, and the half nut 34 is provided in the vicinity of the penetration part of the tie rod 23 of the outer surface of the movable platen 15. Further, the split nut 34 can be moved forward and backward by a drive unit (not shown), and can be locked to the locking portion 35 provided on the tie rod 23 .

In addition, the injection molding machine 11 is provided with a mold opening and closing unit 19 that moves the movable platen 15 (including the movable metal mold 14 ) in the mold opening and closing direction AA, and the rotation of the upper frame and the lower frame 24 as intermediate members. The mold opening and closing unit 20 in which the tray 25 and the intermediate mold 18 move in the mold opening and closing direction AA. As for the mold opening and closing unit 19 of the movable plate (the mold opening and closing unit of the movable metal mold), the drive shaft of the servo motor 37 (M1) fixed to the bed body 12 and the balls supported by the shaft on the bed body 12 The lead screw 38 is connected via a belt member 39 and the like. The servomotor 37 is provided with the rotary encoder 40 which detects the rotation angle. A ball screw nut 41 is fixed to a bracket on the side surface of the movable plate 15 , and the ball screw 38 is inserted into the ball screw nut 41 . In addition, the servo motor 37 is connected to the control device 33 that integrates the entire injection molding machine 11 via the servo amplifier 42 . Although only one movable platen mold opening and closing unit 19 is shown in FIGS. 1 and 2 , two to four movable platen mold opening and closing units 19 are generally provided.

The mold opening and closing unit 20 of the intermediate member (the mold opening and closing unit of the intermediate metal mold) that opens and closes the mold between the movable disk 15 and the intermediate member (rotating disk) 25 is fixed to the bracket on the side surface of the movable disk 15 There is a servo motor 43 (M2). In this figure, a ball screw nut 44 is fixed to the lower frame 24, and a ball screw 45 inserted through the ball screw nut 44 is connected to the drive shaft of the servo motor 43. Furthermore, a rotary encoder 47 is provided in the servo motor 43 . In addition, the servo motor 43 is connected to the control device 33 that integrates the entire injection molding machine 11 via the servo amplifier 48 . In FIGS. 1 and 2 , only one intermediate mold opening/closing unit 20 is shown, but generally two to four intermediate mold opening/closing units 20 are provided. In addition, the attachment of the movable platen mold opening/closing unit 19 and the intermediate member mold opening/closing unit 20, the frame, the connection method of the drive shafts of the servo motors 37, 43 and the ball screws 38, 45, etc. are not limited to this.

In addition, a first injection device 49 is provided on the bed body 12 outside the fixed plate 17 , and a second injection device 50 that moves together with the movable plate 15 is provided outside the movable plate 15 . The number and arrangement of the injection devices 49 and 50 are not limited to these, and the injection devices may be arranged on the side surface of the mold clamping device 13 .

Although the details of the control device 33 are omitted, the control device 33 includes a portion having functions such as an arithmetic unit, a storage unit, an input/output unit, and the like. Furthermore, the control device 33 is connected to the driver and the sensor of each device of the injection molding machine 11 in addition to the above-described mold opening and closing units 19 and 20 . In addition, the control device 33 is connected to the operation unit 31 for inputting and displaying various settings of the injection molding machine 11 .

In addition, on one side of the bed 12 of the injection molding machine 11, an inserting robot 51 for inserting an insert made of a metal material into a predetermined position of the metal mold is arranged. In the present embodiment, a multi-shutdown robot is used as the robot 51 for inserting, and the insert can be grasped by a chuck or a suction tool at the front end. Rails 52 for moving the robot in the mold opening and closing direction AA are arranged on the floor. In addition, the robot 51 can move on the rail 52 in the mold opening and closing direction AA. The reason why the robot 51 can move in this way is to allow the robot 51 to move optimally in a manner that corresponds to any change to the fixed mold 16 , the intermediate mold 18 , or the movable mold 14 to which the mold on which the insert is attached is changed. s position. In addition, although not shown, a robot for taking out the composite body (finished product) of the insert and the resin material is additionally arranged from the metal mold. These robots 51 and the like are also connected to the control device 33 . In addition, the robot 51 for embedding is not limited to an articulated robot, and may be a robot that moves a chuck or the like in the XYZ axes. The molding apparatus of the composite body of the insert and resin material of the present invention includes at least the injection molding machine 11 and the robot 51 .

1 and 2, the first mold is the movable mold 14, the first plate is the movable plate 15, the second mold is the fixed mold 16, and the second plate is the fixed plate 17, but In the present invention, on the contrary, the first metal mold is a fixed metal mold, the first plate is a fixed plate, the second metal mold is a movable metal mold, and the second plate is a movable plate. In addition, in the example of FIG. 1, FIG. 2, the rotary disk 25 and the intermediate mold 18 as the intermediate member move in the mold opening and closing direction AA, but the rotatable intermediate member and the intermediate mold may be opened and closed. Fixed or slightly moved in the mold closing direction, the first mold (movable mold) attached to the first plate (movable plate) on one side, and the second plate (movable plate) attached to the other side. Two metal molds (movable metal molds) move toward the middle metal mold and the middle part.

Next, the method of molding the composite body of the insert and the resin material of the present invention using the injection molding machine 11 for molding the composite body of the insert and the resin material shown in FIGS. 1 and 2 is described with reference to FIGS. 3 to 6 . Be explained. In the present invention, the opened first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are closed, and the resin material M1 is injected into the cavity C1 formed by the above-mentioned mold closing to mold the primary molded product P1 , and hold the mold. The intermediate mold 18 having the above-mentioned primary molded product P1 is rotated and moved to a position opposed to the second mold (fixed mold 16 ) until the intermediate mold 18 and the second mold (fixed mold 16 ) are closed. In any process until the cavity C2 including the primary molded product P1 is formed, the first die (movable die 14 ), the intermediate die 18 , the second die (fixed die 16 ), the first die (movable die 14 ), the second die (fixed die 16 ), At least one insert I of the molded product P1 injects the resin material M2 into the cavity C2 containing the above-described primary molded product P1.

In FIGS. 3 to 6 , the injection molding machine 11 omits the first injection device 49 , the second injection device 50 , and the like, and only the main parts are shown. In addition, the description of the molding method will be described in accordance with the molding procedure of the composite P2 of one insert and the resin material. Therefore, the composite P2 of the insert and the resin material is continuously molded, but the primary molded product P1 and the composite P2 of the insert and the resin material molded in the previous cycle and the next cycle are not shown in FIGS. 3 to 6 . .

First, a method for molding the composite body of the insert and the resin material according to the first embodiment of the present invention shown in FIG. 3 will be described. As shown in FIG. 3( a ), the opened first metal mold (movable metal mold 14 ) or the intermediate metal mold 18 facing the first metal mold (movable metal mold 14 ) passes through a predetermined position The inserting robot 51 performs inserting (inserting into the concave portion of the metal mold) (in this embodiment, the movable metal mold 14 is inserted). As the insert I, the insert I of a rod-shaped or elongated plate-shaped metal material as shown in FIG. 7 is inserted (inserted into the recessed portion of the metal mold). Thereby, the other side of the insert 1 abuts on the cavity surface 14a of the first metal mold (movable metal mold 14). Then, as shown in FIG. 3( b ), the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are closed, and the first metal mold (movable metal mold 14 ) is inserted into the first metal mold (movable metal mold 14 ). The cavity C1 which is one side of the piece I and is formed between the intermediate metal mold 18 is injected with the resin material M1 containing the reinforcing fibers from the second injection device 50 . Then, after a predetermined cooling time has elapsed, as shown in FIG. 3( c ), the first metal mold is held in the intermediate mold 18 in a state where the primary molded product P1 composed of the insert I and the resin material containing the reinforcing fibers is held in the intermediate mold 18 . The mold (movable metal mold 14 ) and the intermediate metal mold 18 are opened. The primary molded product P1 of the present embodiment is a molded product of the finished product shown in FIGS. 7 and 8 , which is composed of the resin material M1 and the insert I and has no resin material M2. As shown in FIG. 8, it is desirable to form non-planar parts such as convex parts M1a, concave parts, and rough surfaces in advance in the part of the resin material M1 to be joined to the resin material M2 during secondary molding to increase the bonding force with the resin material M2.

Then, as described in FIG. 3( d ), the intermediate mold 18 holding the above-mentioned primary molded product P1 and the rotary disk 25 as an intermediate member are rotationally moved to a position facing the second mold (fixed mold 16 ). 180°. Then, as shown in FIG. 3(e), the above-mentioned intermediate metal mold 18 and the second metal mold (fixed metal mold 16) are closed to form the other side of the insert I including the primary molded product P1 and the second metal mold. The cavity C2 between the metal mold (fixed metal mold 16 ) and the intermediate metal mold 18 . Then, the resin material containing reinforcing fibers is injected into the above-mentioned chamber C2, thereby forming a composite of the insert I and the resin material containing reinforcing fibers. Then, as shown in FIG. 3( f ), the mold is opened again, and as shown in FIGS. 7 and 8 , the inserts with resin materials M1 and M2 attached to one side and the other side of the insert I, respectively, and the resin materials are attached. The complex P2 is taken out by a robot not shown. In the above, when the molten resin material is injected into the cavity C1 between the side of the insert I and the first metal mold (movable metal mold 14) through the process of FIG. If molten resin is not injected between the other side of the insert 1 and the intermediate metal mold 18 in the process of 3(e), the resin materials M1 and M2 cannot be formed on both sides of the insert 1. However, if the part between the insert 1 and the intermediate metal mold 18 is not of a special metal mold structure, the cavity space cannot be formed from the time of mold closing, and the cavity C2 is formed due to the pressure of the molten resin following the injection. Therefore, it is not suitable for the injection of molten resin of a fixed amount or more.

In the case of the above-described first embodiment, the resin materials M1 and M2 can be adhered to both surfaces of one side and the other side of the insert I. Therefore, even if the insert I has a relatively thin plate shape or rod shape, the composite P2 of the insert and the resin material is less likely to warp. In addition, when the insert I is a recycled material or a resin body with fibers on the surface, by covering the resin materials M1 and M2 with wood materials on both sides, a composite body of the insert and the resin material with excellent appearance can be formed P2. Furthermore, even if the insert I is of the same length as a metal material (round rod, etc.), since the entire circumference can be covered with resin materials M1 and M2 such as reinforcing fiber materials, a composite body of the insert and the resin material with high strength can be formed. P2.

Next, a method for molding the composite body of the insert and the resin material according to the second embodiment of the present invention shown in FIG. 4 using the injection molding machine 11 for composite body molding shown in FIGS. 1 and 2 will be described. . First, as shown in FIG. 4( a ), from the state where the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are opened, the molds are closed, and as shown in FIG. 4( b ), the mold is formed. The resin material M1 is injected from the second injection device 50 into the cavity C1 between the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 , and the primary molded product P1 made of the resin material is molded. Then, as shown in FIG. 4( c ), the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are opened with the primary molded product P1 held in the intermediate metal mold 18 . Then, the rotary disk 25 and the intermediate mold 18 as the intermediate members holding the above-mentioned primary molded product P1 are rotated and moved to the position facing the second mold (fixed mold 16 ), and then the intermediate mold is moved until the above-mentioned intermediate mold is moved. 18 and the second metal mold (fixed metal mold 16 ) are closed, and one side of the insert I is inserted into the primary molded product P1 so as to be joined. At this time, as shown in FIG. 4( c ), the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are in a state where the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are opposed to each other as shown in FIG. 4( c ). At a predetermined position of the intermediate mold 18 including the primary molded product P1, the intermediate mold 18 and the second mold (fixed mold 16) may be aligned with each other after the intermediate mold 18 is rotated as shown in FIG. 4(d). The insert I is inserted into the predetermined position of the primary molded product P1 in the state of being placed. Furthermore, the insert I may be inserted into a predetermined position of the primary molded product P1 from the side surface of the injection molding machine 11 in a state where the intermediate mold 18 is rotated by 90° to face the direction orthogonal to the mold opening/closing direction AA. . Alternatively, after the primary molded product P1 is formed (after the previous finished product is removed), the insert 1 may be inserted into predetermined positions of the intermediate mold 18 and the second mold (fixed mold).

In this embodiment, after the intermediate mold 18 is rotated as shown in FIG. 4( d ), the insert I is inserted into the primary molded product P1 in a state of facing the second mold (fixed mold 16 ). or the intermediate metal mold 18 . Then, as shown in FIG. 4( e ), the above-mentioned intermediate metal mold 18 and the second metal mold (fixed metal mold 16 ) are closed. Then, the resin material is injected from the first injection device 49 into the cavity C2 formed between the intermediate metal mold 18 and the second metal mold (fixed metal mold 16 ) on the other side containing the insert 1 . Then, when the cooling of the molten resin in the chamber C2 is completed, the mold is opened again as shown in FIG. 4( f ), and the composite P2 of the insert and the resin material is taken out by a robot not shown. In the second embodiment, the insert 1 is not inserted into the cavity C1 of the primary molding, so the stress caused by the heat, pressure, etc. on the insert 1 during molding is smaller than that in the first embodiment. Therefore, it is suitable for the insert I having poor heat resistance and pressure resistance. In addition, when inserting the insert I into the primary molded product P1 held by the intermediate mold 18 and facing the second metal mold (fixed metal mold 16), and injecting from the second injection device 50, it may not be used. The runner structure of the one-shot mold is complicated and completed. However, in the second embodiment, the bond between the primary molded product P1 and the insert I is not strengthened by injection from the first injection device 49 or the like, and becomes weak.

Next, a method for molding the composite body of the insert and the resin material according to the third embodiment of the present invention shown in FIG. 5 using the injection molding machine 11 for composite body molding shown in FIGS. 1 and 2 will be described. . First, as shown in FIG. 5( a ), a first insert is inserted into the opened first metal mold (movable metal mold 14 ) or the intermediate metal mold 18 facing the first metal mold (movable metal mold 14 ) Item 1a. Then, as shown in FIG. 5( b ), the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are closed, and the second injection is made into the chamber C1 containing the inserted first insert Ia. The apparatus 50 injects the resin material M1 to mold the primary molded product P1 composed of the insert and the resin material. Then, as shown in FIG. 5( c ), the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are opened with the primary molded product P1 held in the intermediate metal mold 18 .

Then, as shown in FIG. 5( d ), the intermediate mold 18 holding the above-mentioned primary molded product P1 is rotationally moved to a position opposed to the fixed mold 16 serving as the second mold. Then, until the intermediate mold 18 and the stationary mold 16 are closed, the second insert Ib is fitted into at least one of the primary molded product P1, the intermediate mold 18, and the second mold (the stationary mold 16). Here, the intermediate mold 18 holding the first molded product P1 is fitted with the second insert Ib in a state facing the stationary mold 16 . Then, as shown in FIG. 5( e ), the resin material M2 is injected from the first injection device 49 into the cavity C2 formed by the closed mold and containing the primary molded product P1 and the second insert Ib. Then, when the cooling of the molten resin in the chamber C2 is completed, the mold is opened again as shown in FIG. 5( f ), the insert Ia and the insert Ib are taken out by a robot (not shown), and the integrated insert is taken out. Composite P2 with resin material. In addition, each of the inserts Ia and the inserts Ib is not limited to inserting one, but a plurality of inserts may be inserted.

Next, a method for molding the composite body of the insert and the resin material according to the fourth embodiment of the present invention shown in FIG. 6 using the injection molding machine 11 for composite body molding shown in FIGS. 1 and 2 will be described. First, as shown in FIG. 6( a ), it is fitted into at least one of the first mold (movable mold 14 ) that is opened or the intermediate mold 18 facing the first mold (movable mold 14 ) Insert I. In the fourth embodiment, the insert 1 is not limited to this, and may be a flat-plate prepreg containing reinforcing fibers or a flat-plate-like sheet containing reinforcing fibers. Then, as shown in FIG. 6(b), the first metal mold (movable metal mold 14) and the intermediate metal mold 18 are closed, and the insert I is subjected to additional processing (press molding) in the chamber C1. At this time, heating and cooling in which the first metal mold (movable metal mold 14 ) and the intermediate metal mold 18 are heated in the first half and cooled in the second half may be performed. In addition, when press forming is performed in the cavity C1 between the first die (movable die 14 ) and the intermediate die 18 , the press forming is performed in parallel between the second die (fixed die 14 ) and the intermediate die 18 . In the secondary molding, it is desirable to perform mold closing and locking in advance by the mold opening and closing units 19 and 20 and a locking device provided in the metal mold (not shown).

Then, as shown in FIG. 6( c ), the core 53 , which is a part of the cavity surface of the first metal mold (movable metal mold 14 ) or the intermediate metal mold 18 , is retreated (removed) to form a cavity C1 . Alternatively, the entire movable mold 14 may be retracted to form the cavity C1 containing the insert Ia. Then, the resin material M1 is injected from the second injection device 50 into the chamber C1 containing the press-molded insert Ia, and a primary molded product P1 composed of the insert and the resin material is molded. Then, as shown in FIG.6(d), the 1st metal mold|die (movable metal mold|die 14) and the intermediate metal mold|die 18 are mold-opened in the state which hold|maintained the said primary molded product P1 in the intermediate metal mold|die 18. Then, as shown in FIG.6(e), the intermediate metal mold|die 18 which hold|maintained the said primary molded product P1 is rotated and moved to the position which opposes the 2nd metal mold|die. Then, as shown in FIG. 6( f ), the above-mentioned intermediate metal mold 18 and the second metal mold (fixed metal mold 16 ) are closed, and the mold is closed to the cavity C2 containing the primary molded product P1 formed by the above-mentioned mold closing. The resin material M2 is injected from the first injection device 49 . Then, the composite P2 of the insert and the resin material is molded, and the mold is opened as shown in FIG. 6( g ), and the composite P2 of the insert and the resin material is taken out by a robot not shown.

In addition, the additional processing to the insert I of the fourth embodiment may be performed while the insert I is inserted and the mold is opened. In this case, there are coating of the insert 1, coating for improving the bonding state of the insert 1 and the resin material, preheating of the insert 1, drilling of the insert 1, and the like. In addition, additional processing such as painting may be performed in the cavity C1 formed by closing the mold after inserting the insert I. Alternatively, the insert I may include a reinforcing fiber sheet containing reinforcing fibers, a binder, etc. as the insert I, and inject or inject a low-viscosity molten resin into the above-mentioned sheet in the chamber C1. The resin material is impregnated with the reinforcing fiber-containing sheet. In addition, the material containing the reinforcing fibers may be only the reinforcing fibers.

In addition, the above-described first to fourth embodiments can be used in an appropriate combination within the practicable range. In addition, the number of inserts I to be inserted (inserted, placed) into one of the chambers C1 and C2 is not limited in the case of molding the first molded product and the molding of the composite (finished product) of the insert and the resin material. limited. In addition, the number of the cavities C1 and C2 of the metal mold (the number of finished products of the metal mold) is not limited either. In addition, between the first disk on which the first mold is mounted and the second disk on which the second mold is mounted may be arranged so as to be rotatable about an axis perpendicular to the mold opening direction. The first metal mold of the injection molding machine for the intermediate part of the metal mold is the fixed metal mold 16, the primary molded product P1 is formed between the fixed metal mold 16 and the intermediate metal mold 18, and the second metal mold is the movable metal mold 14. , secondary molding is performed between the movable metal mold 14 and the intermediate metal mold 18 to form a composite P2 of the insert and the resin material. In addition, the injection molding machine 11 of the present invention can, of course, also be used for molding of multi-color molded products and single-color molded products without inserting when the metal mold is replaced.

Next, matters when any one of the first embodiment to the fourth embodiment is used by a combination of an insert of a metal material and injection molding of a reinforcing fiber resin will be described. As described in the Background Art section, in order to reduce the weight of automobiles, it is desirable to use a resin material including a metal material such as high-strength steel, stainless steel, aluminum, and magnesium, and a reinforcing fiber such as carbon fiber or glass fiber, which is called a multi-material. Complex. In addition, in this invention, the insert I of a metal material includes the insert provided with the part of the material other than a metal material.

First, as shown in FIG. 7 , a long-shaped insert I made of a metal material having an engaging portion 61 such as a bolt hole at least at one end is prepared. The insert I made of this metal material is thinner than an insert made of only metal as a finished product, and alone does not have the strength required for an automobile part or the like. In FIG. 7 , the insert I of the metal material is a linear member, but the shape is not limited, such as having a curved portion, having a branch portion, different thicknesses, and the like. Then, in the above-mentioned insert 1, in order to obtain good bonding properties with the reinforcing fiber resins M1 and M2, the metal surface is subjected to sandblasting, laser processing, plasma processing, chemical treatment (chemical etching) before molding of the composite body. ) and other surface treatments. In addition, the composite P2 composed of the metal material and the reinforcing fiber resin may cause electrical corrosion or the like of the metal part due to the potential difference. Therefore, in order to prevent this, it is preferable to coat the surface of the metal material. Furthermore, in the above-described first to fourth embodiments, thermoplastic trees are preferably used for the resin materials M1 and M2 containing reinforcing fibers for injection molding in terms of cost and molding time. These materials are often poor in fluidity during injection, and it is preferable to use a metal mold capable of heating and cooling for the metal mold, or to perform injection compression molding, which is a type of injection molding. When the resin materials M1 and M2 containing reinforcing fibers of the first injection device 49 and the second injection device 50 are covered from both sides as in the first embodiment, the same resin material is preferable. However, when secondary molding is performed by injecting the surface layer from the second injection device 50 to the surface of the primary molded product containing the reinforcing fiber resin, the resin material M1 with fibers exposed on the surface using a recycled material may be molded in one shot. , the secondary molding uses a resin material M2 that does not contain reinforcing fibers or a resin material M2 that contains a lower amount of reinforcing fibers than the primary molding.

In addition, the composite body of the metal material and the reinforcing fiber resin formed by the injection molding machine 11 may be processed to improve the dimensional accuracy when cooling shrinkage, warpage, etc. are completely eliminated. Specifically, the bolt hole and the engaging portion of the metal part may not be formed initially, but additional processing may be performed after forming the composite P2 (finished product) of the insert and the resin material. In addition, in many cases, the bolt hole for engagement and the engagement portion can be formed in a more accurate positional relationship than the bolt hole for engagement and the engagement portion are formed in the metal material before fitting.

The present invention is not listed one by one, but is not limited to the above-described examples of the present embodiment, and those skilled in the art can modify or combine various parts of the above-described embodiments based on the spirit of the present invention. The mold clamping device 13 may be a vertical injection molding machine that opens and closes molds in the longitudinal direction. In the case of a vertical injection molding machine, since the insert is inserted into the upper surface of the metal mold, the insert work itself is often easy.

Claims (7)

1. A method for forming a composite of an insert and a resin material, which is a method for forming a composite of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, characterized in that: Use an injection molding machine that is rotatably mounted around an axis perpendicular to the mold opening direction between the first plate on which the first mold is mounted and the second plate on which the second mold is mounted. Intermediate parts with intermediate metal molds, The opened first metal mold and the intermediate metal mold are closed, A primary molded product is molded by injecting a resin material into the cavity formed by the above-mentioned mold closing, The intermediate metal mold holding the above-mentioned primary molded product is rotated and moved toward the position facing the second metal mold, In any step until the intermediate mold and the second mold are closed to form a cavity containing the primary molded product, the first mold, the intermediate mold, the second mold, and the primary molded product are placed in the mold. at least one of the embedded inserts, The resin material is injected into the cavity containing the above-mentioned primary molded product. 2. A method for forming a composite of an insert and a resin material, which is a method for forming a composite of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, characterized in that: Use an injection molding machine that is rotatably mounted around an axis perpendicular to the mold opening direction between the first plate on which the first mold is mounted and the second plate on which the second mold is mounted. Intermediate parts with intermediate metal molds, Insert the insert into the opened first metal mold or the intermediate metal mold opposite to the first metal mold, Close the first metal mold and the middle metal mold, A primary molded product consisting of the insert and the resin material is molded by injecting the resin material into the cavity on the side containing the inserted insert, The first metal mold and the intermediate metal mold are opened while the above-mentioned primary molded product is held in the intermediate metal mold, The intermediate metal mold holding the above-mentioned primary molded product is rotated and moved toward the position facing the second metal mold, Close the above-mentioned intermediate metal mold and the above-mentioned second metal mold, The resin material is injected into the cavity on the other side of the insert containing the primary molded product formed by the above-described mold closing. 3. A method for forming a composite of an insert and a resin material, which is a method for forming a composite of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, characterized in that: Use an injection molding machine that is rotatably mounted around an axis perpendicular to the mold opening direction between the first plate on which the first mold is mounted and the second plate on which the second mold is mounted. Intermediate parts with intermediate metal molds, Close the first metal mold and the middle metal mold, injecting resin material into the cavity between the first metal mold and the intermediate metal mold, With the primary molded product made of resin material held in the intermediate mold, the first mold and the intermediate mold are opened, The intermediate member and the intermediate metal mold holding the above-mentioned primary molded product are rotated and moved toward the position facing the second metal mold, During the period until the intermediate mold and the second mold are closed, a second insert is inserted into at least one of the primary molded product, the intermediate mold, and the second mold, The resin material is injected into the cavity containing the primary molded product and the second insert formed by the above-described mold closing. 4. A method for forming a composite of an insert and a resin material, which is a method for forming a composite of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, characterized in that: Use an injection molding machine that is rotatably mounted around an axis perpendicular to the mold opening direction between the first plate on which the first metal mold is mounted and the second plate on which the second metal mold is mounted. Intermediate parts with intermediate metal molds, Insert the first insert into the opened first metal mold or the intermediate metal mold opposite to the first metal mold, Close the first metal mold and the middle metal mold, injecting the resin material into the cavity containing the embedded first insert to mold a primary molded product composed of the insert and the resin material, With the above-mentioned primary molded product held in the intermediate mold, the first mold and the intermediate mold are opened, The intermediate metal mold holding the above-mentioned primary molded product is rotated and moved toward the position facing the second metal mold, During the period until the intermediate mold and the second mold are closed, a second insert is inserted into at least one of the primary molded product, the intermediate mold, and the second mold, The resin material is injected into the cavity containing the primary molded product and the second insert formed by the above-mentioned closed mold. 5. A method for forming a composite of an insert and a resin material, which is a method for forming a composite of an insert and a resin material in which the insert and the resin material are integrated in a cavity of a metal mold, characterized in that: Use an injection molding machine that is rotatably mounted around an axis perpendicular to the mold opening direction between the first plate on which the first metal mold is mounted and the second plate on which the second metal mold is mounted. Intermediate parts with intermediate metal molds, Insert the insert into the opened first metal mold or the intermediate metal mold opposite to the first metal mold, While keeping the mold open or after closing the first metal mold and the intermediate metal mold, additional processing is performed on the above-mentioned inserts, A primary molded product consisting of the insert and the resin material is molded by injecting the resin material into the chamber containing the insert that has been additionally processed, With the above-mentioned primary molded product held in the intermediate mold, the first mold and the intermediate mold are opened, The intermediate metal mold holding the above-mentioned primary molded product is rotated and moved toward the position facing the second metal mold, Close the above-mentioned intermediate metal mold and the above-mentioned second metal mold, The resin material is injected into the cavity containing the primary molded product formed by the above-mentioned closed mold. 6 . The method for forming a composite of an insert and a resin material according to claim 1 , wherein: 6 . The above-mentioned inserts are metal materials or materials containing reinforcing fibers. 7. A device for forming a composite body of an insert and a resin material, comprising: An injection molding machine including a metal mold used in the method for molding a composite of an insert and a resin material according to any one of claims 1 to 6; and A robot that is placed on the side of the above-mentioned injection molding machine and inserts an insert into a predetermined position of a metal mold or a primary molded product.

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