CN109291363A - 树脂成型件的生产方法 - Google Patents

树脂成型件的生产方法 Download PDF

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CN109291363A
CN109291363A CN201811184394.5A CN201811184394A CN109291363A CN 109291363 A CN109291363 A CN 109291363A CN 201811184394 A CN201811184394 A CN 201811184394A CN 109291363 A CN109291363 A CN 109291363A
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plate
resin
die cavity
production method
starting position
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加纳则之
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Chuang Nei Industrial Co Ltd
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Abstract

一种插入有分别具有多个通孔的第一和第二板的树脂成型件的生产方法，包括第一和第二板工序，在制造工序中上述板布置成彼此平行且面对。在第一板工序中，第一板在填充有保持高压的熔融树脂的模腔中从第一板开始位置朝第二板侧移动，并返回至第一板开始位置附近的第一板终止位置。在第二板工序中，第二板在模腔中从第二板开始位置朝第一板侧移动，并返回至第二板开始位置附近的第二板终止位置。这使得能够通过板的往复运动将熔融树脂延展到甚至屏蔽区域。即，熔融树脂能够通过板的往复运动前后穿过通孔并最终到达屏蔽区域。因此，熔融树脂延展至第一和第二板的整个表面，从而提高这些板的树脂润湿性。结果，树脂成型件的抗变形强度得以提高。

Description

树脂成型件的生产方法
技术领域
本发明涉及一种树脂成型件的生产方法，该树脂成型件插入有用于加强的第一板和第二板，其中，上述第一加强板具有多个通孔，第二板具有多个通孔。
背景技术
通常，在生产树脂成型件的情况下，需要将插入材料保持在模腔中的固定位置，以避免表面下沉或保持部件痕迹。
关于将插入材料保持在模腔中，公开了一种树脂成型件的生产方法，在该生产方法中，固定销将插入材料保持在模腔中，并且在保持插入材料的位置的情况下，将熔融树脂注入模腔中(在此引用日本公开专利申请H08-25410号作为第一个现有技术)。
在模腔中存在障碍物的情况下，熔融树脂流从被障碍物分开后汇合，并且分流和汇流会在表面造成焊接线、V形切口线等。还公开了一种用于解决这些问题的树脂成型件的生产方法，在该生产方法中，通过柱塞或螺纹位置来调节浇口位置和模腔位置，从而能够控制焊接线位置(在此引用日本公开专利申请第2016-215406号作为第二个现有技术)。还公开了另一种解决措施的技术，在该技术中，通过调节部件来控制熔融树脂流，从而能够控制焊接线的产生(在此引用日本公开专利申请第2010-274439号作为第三个现有技术)。
还公开了另一种树脂成型件的生产方法，在该生产方法中，形成插有插入材料的树脂成型件作为半成品，接着再对半成品实施熔融树脂注塑以制成最终产品(在此引用日本公开专利申请H09-19940号作为第四个现有技术)。
还公开了一种形成模腔并对插入材料进行支承的金属模具，其中，该金属模具具有能够对插入材料进行支承的可滑动部。另外，上述可滑动部能够被熔融树脂子流驱动到后端(在此引用日本公开专利申请第2008-49592号作为第五个现有技术)。
从第一个现有技术到第五个现有技术，插入材料能够被保持在模腔中的固定位置，而避免表面下沉或保持部件痕迹。但是，在那些现有技术中，树脂成型件的总装置规模太大，并且生产工序太多且太复杂。
由于设置在前方和后方处的插入板使得表面拉伸强度增大，因此，具有这些插入板的树脂面板的抗变形性得以加强。另外，在熔融树脂包裹这些插入板且这些插入板与凝固树脂一体化的情况下，表面拉伸强度会变得更强。
还公开了另一种具有插入网的树脂面板(在此引用日本专利第6059841号作为第六个现有技术)。
在这些树脂面板中，在由插入材料形成的、屏蔽熔融树脂流的屏蔽区域处，熔融树脂无法绕到其后部区域，并且因缺少树脂包裹导致的树脂填充不良会导致最终产品的强度不足。
发明内容
本发明基于上述问题点而作，并且本发明的主要目的在于防止在由插入材料形成的屏蔽区域处的树脂填充不良。
在本发明中，插入有具有多个通孔的第一板和具有多个通孔的第二板的树脂成型件的生产方法包括第一板工序和第二板工序，其中，在制造工序期间，所述第一板与所述第二板布置成彼此平行且彼此面对。
在所述第一板工序中，所述第一板在填充有保持高压的熔融树脂的模腔中从第一板开始位置朝所述第二板一侧移动，并返回至所述第一板开始位置附近的第一板终止位置。
在所述第二板工序中，所述第二板在所述模腔中从第二板开始位置朝所述第一板一侧移动，并返回至所述第二板开始位置附近的第二板终止位置。
这使得能够通过板的往复运动将熔融树脂延展到甚至屏蔽区域。即，熔融树脂能够通过板的往复运动而向后和向前穿过多个通孔并最终到达屏蔽区域。
因此，熔融树脂延展至第一板和第二板的整个表面，从而提高这些板的树脂润湿性。其结果是，可防止在板与树脂之间形成空隙，树脂成型件的抗变形的强度得以提高。
在本发明中，所述模腔由上金属模具和下金属模具形成，所述上金属模具和所述下金属模具具有可动杆，所述可动杆由致动器驱动，并能够在所述模腔中分别向前和向后移动。另外，可动杆具有电磁体，所述电磁体能够捕获和释放金属板。在所述第一板终止位置处，切断所述电磁体的电流而使所述可动杆释放所述第一板。在所述第二板终止位置处，切断所述电磁体的电流而使所述可动杆释放所述第二板。
这能够使可动杆结构和运动简单。因此，树脂成型件的总装置规模能够变得紧凑，并且能够减少生产工序的数量。
在本发明中，所述第一板和所述第二板是冲孔金属板。在本领域中能够容易地获得冲孔金属板，因此，能够降低最终产品成本。
在本发明中，所述熔融树脂是包括环氧树脂和聚氨酯树脂的热固性树脂。热固性树脂首先是液体单体，因此，热固性树脂因富有流动性而相对容易到达屏蔽区域。
在本发明中，线缆附接到所述第一板或所述第二板。
这使得能够省略将线缆附接到树脂成型件的工序。
附图说明
在附图中，对本发明的优选形式进行说明，其中：
图1是根据本发明第一实施方式的树脂成型件的立体图，其中，上述树脂成型件插入有具有多个通孔的第一板和具有多个通孔的第二板；
图2是树脂成型装置的纵剖视图；
图3至图7是下金属模具周围的纵剖视图；
图8是从金属模具中移除树脂成型件时的纵剖视图；
图9是致动器的框图；
图10是根据本发明第二实施方式的树脂成型件的立体图，其中，上述树脂成型件设置有连通用的线缆；
图11是树脂成型件的纵剖视图。
具体实施方式
在所描述的实施方式的以下说明中，对相同类型的特征使用相同的附图标记。
参照图1至图9，示出了根据本发明第一实施方式的树脂成型件的生产方法，其中，上述树脂成型件插入有具有多个通孔的第一板和具有多个通孔的第二板。
如图1所示，树脂成型件1插入有：第一板10，该第一板10具有多个通孔10a；以及第二板11，该第二板11具有多个通孔11a。并且，如图2所示，树脂成型件1由树脂成型装置2形成。
如图1所示，树脂成型装置2形成所有表面均覆盖了树脂材料3A的树脂成型件1。
例如，第一板10和第二板11是分别具有多个通孔10a和11a的薄冲孔金属板(例如，它们的厚度t为0.05mm-3.0mm)，其呈六边形且布置成蜂窝状。
冲孔金属板是磁性物质金属板，并且高密度地具有多个通孔。并且，第一板10和第二板11仅需要是加强的且能被容易地磁化。因此，第一板10和第二板11并非必须是冲孔金属板。例如，第一板10和第二板11可以是能被容易地磁化的网、扩张金属、织物或树脂。
如图2所示，树脂成型装置2具有金属模具3，上述金属模具3由上金属模具3a和下金属模具3b组成。并且，上金属模具3a和下金属模具3b通过模腔形成部4a将模腔分开。并且，树脂成型件1轮廓由模腔形成部4a的形状确定。
在模腔中，第一板10与第二板11布置成彼此平行且彼此面对。然后，将熔融树脂4注入模腔，从而形成插入有第一板10和第二板的树脂成型件1。并且，模腔形成部4a的、布置成彼此平行且彼此面对的上平面和下平面在下文分别被称为第一内平面4c和第二内平面4d。
熔融树脂4包括热固性树脂和热塑性树脂。并且，熔融树脂4能够选自聚丙烯、聚苯乙烯、环氧树脂和聚氨酯等，包括工程塑料。因此，能够降低树脂成型件1的价格，以选择更廉价的材料。
在图中的下金属模具3b的左侧处，设置有注塑浇口5，而在图中的下金属模具3b的中心处能滑动地设有推针5A，上述推针5A能够将树脂成型件1推出。在推针5A的两侧处设置有一对通孔6，一对上述通孔6穿过下金属模具3b的底部。
并且，对于每个通孔6均能滑动地设置有可动杆7。可动杆7由致动器8驱动，并且能够在模腔中分别向前和向后移动。一对通孔6a和可动杆7也设置于上金属模具3a。
每个可动杆7具有电磁体15，上述电磁体15能够捕获和释放金属板。电磁体15的电磁体电流由控制器16a根据第一板10和第二板11的位置进行控制。并且，在通孔6、6a处插入有导电管15a。因此，电磁体15与控制器16a通过导电管15a连接。例如，致动器8具有活塞17、缸18以及驱动设备Ps，上述驱动设备Ps具有油箱Ts。
在上金属模具3a周围，活塞17连接到可动杆7的上端，并且通过例如压缩螺旋弹簧19始终从模腔中心Px偏置到第一内平面4c。
驱动设备Ps由控制器20控制。
如图3所示，在将熔融树脂4作为熔融树脂流4h注入之前，将电流输送到电磁体15，以将第二板11设在第二板开始位置V0处。
然后，将熔融树脂4注入模腔。最后，模腔填充有保持高压的熔融树脂4。
在这种情况下，第二板11在模腔中从第二板开始位置V0朝第一板10一侧、即模腔中心Px一侧移动，并返回至第二板终止位置P4。
如图4所示，致动器8驱动可动杆7进入模腔，上述可动杆7通过电磁体15连接到第二板11。因此，第二板11从第二板开始位置V0移动预定距离P1。
在该工序中，熔融树脂流4h穿过通孔11a，在图中示出为下降流。
然后，如图5所示，第二板11朝第二板终止位置P4返回。
在该工序中，熔融树脂流4h穿过通孔11a，在图中示出为上升流。
如图6所示，第二板11停止在第二板开始位置V0附近的第二板终止位置P4处。第二板11与第二内平面4d之间的间隙定义为P2。
如图7所示，在第二板终止位置P4处，切断电磁体15的电流，通过使用致动器8使可动杆7返回至第二板开始位置V0。
由于电磁体15的电流被切断，因此，第二板11留在第二板终止位置P4处。并且，在第二板开始位置V0处，电磁体15的上平面15c与第二内平面4d布置成齐平。
并且，熔融树脂4延展到每个角落，从而使模腔填充有树脂材料3A。
在上金属模具3a处，可动杆7在填充有保持高压的熔融树脂4的模腔中以相同的动作运转。
因此，第一板10从第一板开始位置U0朝第二板11一侧、即模腔中心Px一侧移动。
在该工序中，熔融树脂流4h作为上升流，穿过通孔10a。
之后，第一板10朝第一板终止位置P3返回。
在该工序中，熔融树脂流4h作为下降流，穿过通孔10a。
在第一板终止位置P3处，切断电磁体15的电流，并通过使用致动器8使可动杆7返回至第一板开始位置U0。
由于电磁体15的电流被切断，因此，第一板10留在第一板终止位置P3处。并且，在第一板开始位置U0处，电磁体15的上平面15c与第一内平面4c布置成齐平。
并且，熔融树脂延展至每个角落，从而使模腔和下金属模具3b填充有树脂材料3A。
如图8所示，在已完成成型件之后，通过自动定时器控制的致动器，打开金属模具3。
之后，推针5A被致动器驱动，从而使树脂成型件1被推离金属模具3。
如图9所示，在金属模具3打开且第一板10和第二板11分别设在第一板开始位置U0和第二板开始位置V0处的情况下，电流通过由ECU 20指令的控制器16a而被输送到电磁体15。因而，电磁体15分别捕获第一板10和第二板11。
之后，驱动设备Ps将油从油箱Ts输送到缸18，以驱动活塞17克服压缩螺旋弹簧19的力。
然后，可动杆7被朝模腔中心Px一侧驱动，因此，第一板10和第二板11能够分别朝模腔中心Px一侧移动。
通过位置传感器来检测第一板10和第二板11的现当前位置。在第一板10和第二板11到达预定距离之后，ECU 20指令驱动设备Ps使第一板10和第二板11返回。
之后，缸18使油返回到油箱Ts，通过压缩螺旋弹簧19的力使活塞17返回，使可动杆7返回，从而使第一板10和第二板11分别返回至第一板终止位置P3和第二板终止位置P4。
然后，在第一板终止位置P3处切断电磁体15的电流，从而使可动杆7释放第一板10，在第二板终止位置P4处切断电磁体15的电流，从而使可动杆7释放第二板11。
另外，在第一板10留在第一终止端位置P3而第二板11留在第二板终止位置P4的情况下，可动杆7返回至第一板开始位置U0和第二板开始位置V0。最后，电磁体15的上平面15c与第一内平面4c或第二内平面4d布置成齐平，并使驱动设备Ps停止。
在第一实施方式中，第一板10(第二板11)从第一板开始位置U0(第二板开始位置V0)朝模腔中心Px一侧移动，并返回至第一内平面4c(第二内平面4d)的附近位置。
如图4和图5所示，这使得熔融树脂流4h能够利用板的往复运动而向前和向后穿过多个通孔10a、11a。
因此，熔融树脂流4h甚至能够到达由第一板10(第二板11)和第一内平面4c(第二内平面4d)形成的窄间隙Pw。
因此，熔融树脂延展至第一板10(第二板11)的整个表面，从而提高这些板的树脂润湿性。
其结果是，可防止在金属板与树脂之间形成空隙，树脂成型件、例如树脂面板的抗变形的强度得以提高。
顺带一提，在使用热固性树脂作为熔融树脂4的情况下，第一板10(第二板11)的表面被均等地压缩，以使树脂材料3A固化收缩，因此，树脂成型件1的强度得以提高，从而改善板与树脂材料之间的粘合性。并且，在使用注塑成型的情况下，随着树脂材料3A热收缩，树脂成型件1的强度也得以提高。
参照图10和图11，示出了根据第二实施方式的树脂成型件1的生产方法，其中，上述树脂成型件1插入有具有多个通孔10a的第一板10和具有多个通孔11a的第二板11。
在第二实施方式中，线缆40附接到第一板10的靠模腔一侧。
这使得线缆40能够嵌入熔融树脂4(树脂材料3A)。因此，能够省略线缆40附接到树脂成型件1的附接工序。并且由于树脂材料3A是绝缘体，因此，线缆40不需要被涂覆。
变形形式
模腔不仅可以填充保持高压的熔融树脂，还可以填充保持常压的熔融树脂。
可动杆7的数量不仅可以是一对，还可以是一个、三个等。
通孔10a、11a不仅可以呈六边形，还可以呈圆形、矩形、五边形等形状。并且通孔6、6a可以根据通孔10a、11a选择合适的形状。
第一板10和第二板11不仅可以采用平板，还可以采用曲面板。
通孔10a、11a的密度分布不仅可以是均匀的，还可以是不均匀的。

Claims (5)

1.一种树脂成型件的生产方法，其中，所述树脂成型件插入有具有多个通孔的第一板和具有多个通孔的第二板，在制造工序期间，所述第一板与所述第二板布置成彼此平行且彼此面对，所述生产方法包括：
第一板工序，在所述第一板工序中，所述第一板在填充有保持高压的熔融树脂的模腔中，从第一板开始位置朝所述第二板一侧移动，并返回至所述第一板开始位置附近的第一板终止位置；以及
第二板工序，在所述第二板工序中，所述第二板在所述模腔中从第二板开始位置朝所述第一板一侧移动，并返回至所述第二板开始位置附近的第二板终止位置。
2.如权利要求1所述的生产方法，其特征在于，所述模腔由上金属模具和下金属模具形成，所述上金属模具和所述下金属模具具有可动杆，所述可动杆由致动器驱动，并且能够在所述模腔中分别向前和向后移动，并且所述可动杆具有电磁体，所述电磁体能够捕获和释放金属板，在所述第一板终止位置处，切断所述电磁体的电流而使所述可动杆释放所述第一板，在所述第二板终止位置处，切断所述电磁体的电流而使所述可动杆释放所述第二板。
3.如权利要求1所述的生产方法，其特征在于，所述第一板和所述第二板是冲孔金属板。
4.如权利要求1所述的生产方法，其特征在于，所述熔融树脂是包括环氧树脂和聚氨酯树脂的热固性树脂。
5.如权利要求1所述的生产方法，其特征在于，线缆附接到所述第一板或所述第二板。
CN201811184394.5A 2018-03-06 2018-10-11 树脂成型件的生产方法 Pending CN109291363A (zh)

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