CN111331778A

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

Info

Publication number: CN111331778A
Application number: CN201911276862.6A
Authority: CN
Inventors: 菊川雅之
Original assignee: Japan Steel Works Ltd
Current assignee: Japan Steel Works Ltd
Priority date: 2018-12-19
Filing date: 2019-12-12
Publication date: 2020-06-26
Also published as: JP6844933B2; JP2020097206A

Abstract

The invention provides a method for molding a composite of an insert and a resin material and an apparatus for molding a composite of an insert and a resin material, which can cope with molding with various changes including molding in which resin is adhered to both sides of an insert. A method for manufacturing a primary molded article (P1) by injection molding of a resin material (M1) into a cavity (C1) formed by closing an opened first metal mold (14) and an intermediate metal mold (18), and rotationally moving the intermediate metal mold holding the primary molded article (P1) toward a position facing a second metal mold, wherein at least one insert (I) of the first metal mold (14), the intermediate metal mold (18), the second metal mold (16), and the primary molded article (P1) is inserted into at least one insert (I) in an arbitrary step until the intermediate metal mold and the second metal mold are closed to form a cavity (C2) containing the primary molded article (P1), and the resin material (M2) is injected into the cavity (C2).

Description

Method and apparatus for molding composite of insert and resin material

Technical Field

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

Background

Conventionally, in the field of weight reduction of automobiles and the like, use of resin materials such as reinforcing fiber resin materials has been increasing. However, a molded article made of only a resin material such as a reinforcing fiber material has problems of strength, joining to other members, molding accuracy, and the like, and a composite of a metal material called a multi-material and a resin material such as a reinforcing fiber resin material is being developed. Patent document 1 discloses a method for molding a composite of a metal material and a reinforcing fiber resin material by thermocompression bonding, and also discloses a method for molding a composite of a metal material and a reinforcing fiber resin material by injection molding in fig. 7.

Patent document 2 describes a method of molding a composite of a metal material and a reinforcing fiber resin material by injection molding a surface layer and then a core layer in a state where an extrusion pin as an insert is inserted into a cavity. Patent document 2 also describes that a cylindrical insert of a metal tube is inserted after a part of the surface layer is removed from the molded article.

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication 2016-55539 (claim 3, paragraph 0047, FIG. 7)

Patent document 2: japanese patent laid-open publication No. 10-24447 (claims 1, paragraphs 0012, 0013, FIG. 3)

Disclosure of Invention

Problems to be solved by the invention

These methods of molding a composite of an insert and a resin material using injection molding can join the insert and the resin material together with the injection molding of the resin, and therefore productivity is often superior to other molding methods. However, the molding method of the composite of the insert and the resin material of patent documents 1 and 2 has a problem that it is difficult to cope with various molding methods as described below.

Specifically, in the molding methods of patent documents 1 and 2, since the insert made of the metal material to be inserted is brought into contact with the metal mold, the reinforcing fiber resin material can be attached to only one surface of the insert, and there is a problem that it is difficult to attach the reinforcing fiber resin material to the entire periphery of the insert. In addition, since insert molding and injection molding are generally performed using a single mold, there is a problem that molding restrictions are imposed when resin materials of different types and properties are injection molded. In addition, since a single metal mold is generally used, it is difficult to perform molding in which a portion of an insert made of a metal material, a reinforcing fiber, or the like is subjected to various changes such as further processing, coating, or preheating. Further, if the molding with the variation is performed on a single mold, the molding cycle is extended.

In view of the above problems, an object of the present invention is to provide a method for molding a composite of an insert and a resin material and an apparatus for molding a composite of an insert and a resin material, which can cope with molding with various modifications including molding in which resin is adhered to both sides of an insert.

Means for solving the problems

A method of molding a composite of an insert and a resin material according to claim 1 of the present invention is a method of molding a composite of an insert and a resin material in which an insert and a resin material are integrated in a cavity of a mold, characterized by using an injection molding machine in which an intermediate member to which an intermediate mold is attached is rotatably disposed between a first tray to which a first mold is attached and a second tray to which a second mold is attached around an axis orthogonal to a mold opening direction, closing the first mold and the intermediate mold that have been opened, injecting a resin material into a cavity formed by the closing to mold a primary molded article, rotationally moving the intermediate mold holding the primary molded article toward a position facing the second mold, and in an arbitrary step until the intermediate mold and the second mold are closed to form a cavity including the primary molded article, a resin material is injected into a cavity including a primary molded article by inserting an insert into at least one of a first mold, an intermediate mold, a second mold, and the primary molded article.

A method of molding a composite of an insert and a resin material according to claim 2 of 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 mold, characterized by using an injection molding machine in which an intermediate member to which an intermediate mold is attached is rotatably disposed between a first plate to which a first mold is attached and a second plate to which a second mold is attached about an axis orthogonal to a mold opening direction, inserting the insert into the first mold that is opened or the intermediate mold that faces the first mold, closing the first mold and the intermediate mold, injecting the resin material into the cavity on the side including the inserted insert to mold a primary molded article composed of the insert and the resin material, and opening the first mold and the intermediate mold while holding the primary molded article in the intermediate mold And a mold configured to rotate the intermediate mold holding the primary molded article toward a position facing a second mold, to close the intermediate mold and the second mold, and to inject a resin material into a cavity on the other side of the insert including the primary molded article formed by the closing.

A method of molding a composite of an insert and a resin material according to claim 3 of 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 mold, characterized by using an injection molding machine in which an intermediate member to which an intermediate mold is attached is disposed between a first tray to which the first mold is attached and a second tray to which the second mold is attached so as to be rotatable about an axis orthogonal to a mold opening direction, closing the first mold and the intermediate mold, injecting the resin material into the cavity between the first mold and the intermediate mold, opening the first mold and the intermediate mold while holding a primary molded article made of the resin material in the intermediate mold, and rotationally moving the intermediate member and the intermediate mold holding the primary molded article toward a position facing the second mold, and a step of fitting a second insert into at least one of the primary molded article, the intermediate mold, and the second mold until the intermediate mold and the second mold are closed, and injecting a resin material into a cavity including the primary molded article and the second insert, the cavity being formed by the closing.

A method of molding a composite of an insert and a resin material according to claim 4 of 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 mold, characterized by using an injection molding machine in which an intermediate member to which an intermediate mold is attached is disposed between a first plate to which a first mold is attached and a second plate to which a second mold is attached so as to be rotatable about an axis orthogonal to a mold opening direction, fitting the first insert into the first mold that has been opened or the intermediate mold that faces the first mold, closing the first mold and the intermediate mold, injecting the resin material into the cavity including the first insert that has been fitted, molding a primary molded article including the insert and the resin material, and holding the primary molded article in the intermediate mold, opening the first mold and the intermediate mold, rotationally moving the intermediate mold holding the primary molded article toward a position facing the second mold, fitting a second insert into at least one of the primary molded article, the intermediate mold, and the second mold until the intermediate mold and the second mold are closed, and injecting a resin material into a cavity including the primary molded article and the second insert formed by the closing.

A method of molding a composite of an insert and a resin material according to claim 5 of the present invention is a method of molding a composite of an insert and a resin material in which an insert and a resin material are integrated in a cavity of a mold, characterized by using an injection molding machine in which an intermediate member to which an intermediate mold is attached is rotatably disposed between a first plate to which a first mold is attached and a second plate to which a second mold is attached around an axis orthogonal to a mold opening direction, inserting the insert into the first mold opened or the intermediate mold facing the first mold, performing an additional process on the insert while the mold is opened or after the first mold and the intermediate mold are closed, and injecting a resin material into the cavity including the insert further subjected to the additional process to mold a primary molded article composed of the insert and the resin material, the method includes opening a first mold and an intermediate mold while holding the primary molded article in the intermediate mold, rotationally moving the intermediate mold holding the primary molded article toward a position facing a second mold, closing the intermediate mold and the second mold, and injecting a resin material into a cavity including the primary molded article formed by the closing.

Claim 6 of the present invention is the method of forming a composite of an insert and a resin material according to any one of claims 1 to 5, wherein the insert is made of a metal material or a material containing reinforcing fibers.

The apparatus for molding a composite of an insert and a resin material according to claim 7 of the present invention includes: an injection molding machine including a mold used in the method of molding the composite of the insert and the resin material according to any one of claims 1 to 6; and a robot disposed at a side of the injection molding machine and configured to insert the insert into a predetermined position of the mold or the primary molded article.

ADVANTAGEOUS EFFECTS OF INVENTION

The method of 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 an insert and a resin material are integrated in a cavity of a mold, wherein an injection molding machine is used, the injection molding machine being configured to arrange an intermediate member to which an intermediate mold is attached between a first tray to which a first mold is attached and a second tray to which a second mold is attached so as to be rotatable about an axis orthogonal to a mold opening direction, the mold is closed with the first mold and the intermediate mold opened, the resin material is injected into the cavity formed by the mold closing to mold a primary molded article, the intermediate mold holding the primary molded article is rotationally moved to a position facing the second mold, and the intermediate mold and the second mold are closed to form a cavity including the primary molded article, the insert molding apparatus according to the present invention is characterized in that the insert molding apparatus further includes a resin material injection unit that injects a resin material into a cavity including the primary molded product, and the resin material injection unit is configured to inject the resin material into the cavity.

Drawings

Fig. 1 is a plan view of an injection molding machine according to an embodiment of the present invention, showing a state when the mold is opened.

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

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

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

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

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

Fig. 7 is a front view of a composite 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 B-B of fig. 7.

In the figure:

11-injection molding machine, 13-mold clamping device, 14-movable metal mold, 15-movable platen, 16-fixed metal mold, 17-fixed platen, 18-intermediate metal mold, 25-intermediate part (rotating platen), 49-first injection device, 50-second injection device, C0, C1, C2-cavity, I, Ia, Ib-insert, M1, M2-resin material, P1-primary molded article, P2-complex of insert and resin material (finished product).

Detailed Description

An injection molding machine 11 according to an embodiment of the present invention will be described with reference to fig. 1 and 2. The injection molding machine 11 is an injection molding machine 11 for molding a composite of the insert I and the resin materials M1, M2. A mold clamping device 13 is disposed on the upper surface of the bed 12. The mold clamping device 13 is disposed such that a rotary platen 25 as an intermediate member to which the intermediate mold 18 is attached is movable in the mold opening/closing direction a-a between a movable platen 15 as a first platen to which the movable mold 14 as a first mold is attached and a fixed platen 17 as a second platen to which the fixed mold 16 as a second mold is attached and is rotatable about an axis O orthogonal to the mold opening direction. The fixed mold 16 and the intermediate mold 18, and the movable mold 14 and the intermediate mold 18 are closed by mold opening and

closing units

19 and 20, respectively, to form a first chamber C1 and a second chamber C2, respectively, and are closed by a mold closing unit 21.

A clamping cylinder 22 of the clamping unit 21 is provided near the four corners of the fixed platen 17, and a link of the clamping cylinder 22 is a tie bar 23. Further, a movable platen 15 movable in the mold opening/closing direction a-a with respect to the fixed platen 17, and an upper frame (not shown) and a lower frame 24 which are positioned between the fixed platen 17 and the movable platen 15 and movable in the mold opening/closing direction a-a are inserted into the tie rod 23. A rotary disk 25 as an intermediate member is rotatably disposed between the upper frame of the two tie rods 23 inserted on the upper side and the lower frame 24 of the two tie rods 23 inserted on the lower side about an axis orthogonal to the mold opening and closing direction a-a. The intermediate molds 18 are mounted on the mold mounting surfaces on both sides of the rotary platen 25. The intermediate mold 18 is provided with a shape improvement or device for holding the primary molded product P1 at the time of mold release.

In addition, in the above, the lower frame 24 may also be supported on the bed 12. In addition, the upper frame may be omitted. The upper frame and the lower frame 24 may be omitted, a moving member not guided by the tie bar 23 may be provided on the bed 12 so as to be movable in the mold opening/closing direction a-a, a rotary table (intermediate member) rotatable with respect to the moving frame may be provided upright, and the intermediate molds may be mounted on the mold mounting surfaces on both surfaces of the rotary table. Further, one intermediate mold having cavity surfaces on both or four sides may be attached to the upper surface of the rotatable rotary table on the upper surface of the moving member. In this case, the rotary table corresponds to the intermediate member. Further, one intermediate mold to which a mold portion is attached may be rotatably attached between the upper frame and the lower frame 24 on both sides of the intermediate member portion. In each example of the present invention, the rotatable intermediate member means that the intermediate member is intermittently rotated repeatedly in one direction, and includes normal rotation and reverse rotation at an angle of 180 ° or the like.

The clamping cylinder 22 is hydraulically operated, and working oil is supplied from a pump 27 connected to the tank 26 to a clamping side oil chamber 29a or an opening side oil chamber 29b of the clamping cylinder 22 via a switching valve 28. The mold clamping unit is not limited to the mold clamping cylinder 22 shown in fig. 1. The movable die 14 is attached to the movable platen 15, and a half nut 34 is provided near the insertion portion of the tie bar 23 on the outer surface of the movable platen 15. The split nut 34 is movable forward and backward by a driving means not shown, and is engageable with an engaging portion 35 provided on the tie rod 23.

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 a-a, and a mold opening and closing unit 20 that moves the upper frame, the lower frame 24, the rotary platen 25 as an intermediate member, and the intermediate metal mold 18 in the mold opening and closing direction a-a. The movable platen mold opening/closing unit 19 (movable mold opening/closing unit) is connected to a drive shaft of a servomotor 37(M1) fixed to the bed 12 and a ball screw 38 pivotally supported by the bed 12 via a belt member 39 or the like. The servomotor 37 is provided with a rotary encoder 40 that detects the rotation angle. A ball screw nut 41 is fixed to a bracket on the side surface of the movable disk 15, and the ball screw 38 is inserted into the ball screw nut 41. The servomotor 37 is connected to a control device 33 that integrates the entire injection molding machine 11 via a servo amplifier 42. Fig. 1 and 2 show only one movable-disk mold opening and closing unit 19, but generally 2 to 4 movable-disk mold opening and closing units 19 are provided.

In the mold opening and closing unit 20 (mold opening and closing unit of the intermediate metal mold) for opening and closing the mold between the movable platen 15 and the intermediate member (rotary platen) 25, a servomotor 43(M2) is fixed to a bracket on the side surface of the movable platen 15, a ball screw nut 44 is fixed to the lower frame 24 in the figure, and a ball screw 45 inserted through the ball screw nut 44 is coupled to a drive shaft of the servomotor 43. The servomotor 43 is provided with a rotary encoder 47. The servo motor 43 is connected to a control device 33 that integrates the entire injection molding machine 11 via a servo amplifier 48. Fig. 1 and 2 show only one mold opening and closing unit 20 of the intermediate member, but generally, 2 to 4 mold opening and closing units 20 of the intermediate member are provided. The members to which the movable platen mold opening/closing unit 19 and the intermediate mold opening/closing unit 20 are attached, the frame, and the method of connecting the drive shafts of the

servo motors

37 and 43 to the ball screws 38 and 45 are not limited to these.

Further, a first injection device 49 is provided on the bed 12 outside the fixed tray 17, and a second injection device 50 that moves together with the movable tray 15 is provided outside the movable tray 15. The number and arrangement of the

injection devices

49 and 50 are not limited to this, and the injection devices may be arranged on the side surface side of the mold clamping device 13.

The control device 33 has a part having functions of an arithmetic unit, a storage unit, an input/output unit, and the like, although details thereof are omitted. The control device 33 is connected to actuators and sensors of the respective devices of the injection molding machine 11 in addition to the mold opening and

closing units

19 and 20. The control device 33 is connected to an operation unit 31 for inputting and displaying various settings of the injection molding machine 11.

Further, an insertion robot 51 for inserting an insert made of a metal material into a predetermined position of a mold is disposed on one side of the bed 12 of the injection molding machine 11. In the present embodiment, the fitting robot 51 is a multi-robot, and can hold the insert by a chuck or a suction tool at the tip. A rail 52 for moving the robot in the mold opening/closing direction A-A is disposed on the floor surface. The robot 51 is movable on the rail 52 in the mold opening/closing direction a-a. The robot 51 is movable in such a manner that the robot 51 can be moved to an optimum position in a corresponding manner regardless of whether the insert-attached mold is changed to the fixed mold 16, the intermediate mold 18, or the movable mold 14. Further, although not shown, a robot for taking out the composite (finished product) of the insert and the resin material from the mold is additionally disposed. These robots 51 and the like are also connected to the control device 33. The robot 51 for fitting is not limited to the articulated robot, and may be a robot that moves a chuck or the like in XYZ axial directions. The apparatus for molding a composite of an insert and a resin material of the present invention includes at least an injection molding machine 11 and a robot 51.

In the example shown in fig. 1 and 2, the first mold is a movable mold 14, the first platen is a movable platen 15, the second mold is a fixed mold 16, and the second platen is a fixed platen 17, but in the present invention, the first mold may be a fixed mold, the first platen is a fixed platen, the second mold may be a movable mold, and the second platen is a movable platen. In the example of fig. 1 and 2, the rotary disk 25 and the intermediate metal mold 18 as the intermediate members move in the mold opening/closing direction a-a, but the rotatable intermediate members and the intermediate metal molds may be fixed or slightly moved in the mold opening/closing direction, and the first metal mold (movable metal mold) attached to the first disk (movable disk) on one side and the second metal mold (movable metal mold) attached to the second disk (movable disk) on the other side may be moved toward the intermediate metal mold and the intermediate members.

Next, a method of molding a composite of an insert and a resin material according to the present invention using the injection molding machine 11 for molding a composite of an insert and a resin material shown in fig. 1 and 2 will be described with reference to fig. 3 to 6. In the present invention, a first mold (movable mold 14) and an intermediate mold 18 which have been opened are closed, a resin material M1 is injected into a cavity C1 formed by the closed mold to form a primary molded product P1, the intermediate mold 18 holding the primary molded product P1 is rotated and moved toward a position facing a second mold (fixed mold 16), and in an arbitrary step until the intermediate mold 18 and the second mold (fixed mold 16) are closed to form a cavity C2 including the primary molded product P1, at least one insert I of the first mold (movable mold 14), the intermediate mold 18, the second mold (fixed mold 16), and the primary molded product P1 is injected into the cavity C2 including the primary molded product P1, the resin material M2 is injected into the cavity C2.

In fig. 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 portions are shown. The description of the molding method is made in accordance with the molding procedure of the composite P2 of one insert and the resin material. Therefore, although the insert-resin composite P2 is continuously molded, the illustration of the insert-resin composite P1 and the illustration of the insert-resin composite P2 that are molded in the previous cycle and the next cycle are omitted in fig. 3 to 6.

First, a method of molding a composite of an insert and a resin material according to a first embodiment of the present invention shown in fig. 3 will be described. As shown in fig. 3 a, fitting (insertion into a concave portion of a metal mold) is performed by a fitting robot 51 at a predetermined position of the first metal mold (movable metal mold 14) opened or the intermediate metal mold 18 facing the first metal mold (movable metal mold 14) (in this embodiment, fitting of the movable metal mold 14). The insert I is a rod-shaped or long plate-shaped metal material insert I as shown in fig. 7 (which is inserted into a recess of a die). Thereby, the other side of the insert I abuts against 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 a resin material M1 containing reinforcing fibers is injected from the second injection device 50 into a cavity C1 formed between the first metal mold (movable metal mold 14) and the intermediate metal mold 18 and containing an insert I inserted into the first metal mold. After a predetermined cooling time has elapsed, the first metal mold (movable metal mold 14) and the intermediate metal mold 18 are opened while the primary molded article P1 made of the insert I and the resin material containing the reinforcing fibers is held by the intermediate metal mold 18 as shown in fig. 3 (c). The primary molded article P1 of the present embodiment is a molded article that is composed of the resin material M1 and the insert I and has no portion of the resin material M2 in the finished product shown in fig. 7 and 8. In the resin material M1, it is desirable that a portion to be joined to the resin material M2 during secondary molding is formed in advance with a non-planar portion such as a convex portion M1a, a concave portion, and a rough surface as shown in fig. 8 so that the joining force with the resin material M2 is increased.

Then, as shown in fig. 3(d), the intermediate mold 18 holding the primary molded product P1 and the turntable 25 serving as an intermediate member are rotated by 180 ° toward a position facing the second mold (the fixed mold 16). Then, as shown in fig. 3 e, the intermediate mold 18 and the second mold (the fixed mold 16) are closed to form a cavity C2 including the other side of the insert I of the primary molded article P1 and between the second mold (the fixed mold 16) and the intermediate mold 18. Then, a resin material containing reinforcing fibers is injected into the cavity C2, thereby forming a composite of the insert I and the resin material containing reinforcing fibers. Then, the mold is opened again as shown in fig. 3(f), and the composite P2 of the insert and the resin material, in which the resin materials M1 and M2 are respectively adhered to one side and the other side of the insert I as shown in fig. 7 and 8, is taken out by a robot (not shown). In the above-described case where the molten resin material is injected into the cavity C1 between one side of the insert I and the first metal mold (movable metal mold 14) in the step of fig. 3(b), if the molten resin is not injected between the other side of the insert I and the intermediate metal mold 18 in the step of fig. 3(e), the resin materials M1 and M2 cannot be formed on both sides of the insert I. However, when the portion between the insert I and the intermediate mold 18 is not a special mold structure, a cavity space is not formed from the time of mold closing, and the cavity C2 is formed by the pressure of the molten resin along with injection, so that it is not suitable for injection of the molten resin of a fixed amount or more.

In the case of the first embodiment, the resin materials M1 and M2 can be attached to both the one side and the other side of the insert I. Therefore, even if the insert I is relatively thin plate-like or rod-like, the composite P2 of the insert and the resin material is less likely to warp. In addition, when the insert I is a recyclable insert or a resin body having fibers on the surface thereof, a composite P2 of the insert and the resin material having excellent appearance can be formed by covering both surfaces with the resin materials M1 and M2 made of a wood material. Further, even if the insert I is of a long condition (such as a round bar) such as a metal material, since the entire periphery can be covered with the resin materials M1 and M2 such as a reinforcing fiber material, the composite P2 of the insert and the resin material having high strength can be formed.

Next, a method of molding a composite of an insert and a resin material according to a second embodiment of the present invention shown in fig. 4 using the injection molding machine 11 for molding a composite shown in fig. 1 and 2 will be described. First, from a state in which the first mold (movable mold 14) and the intermediate mold 18 are opened as shown in fig. 4(a), the mold is closed, and as shown in fig. 4(b), the resin material M1 is injected from the second injection device 50 into the cavity C1 formed between the first mold (movable mold 14) and the intermediate mold 18, and the primary molded article P1 made of the resin material is molded. Then, as shown in fig. 4(c), the first mold (movable mold 14) and the intermediate mold 18 are opened with the primary molded article P1 held in the intermediate mold 18. Then, the turntable 25 and the intermediate mold 18, which are intermediate members holding the primary molded article P1, are rotated and moved toward positions facing the second mold (the fixed mold 16), and then one side of the insert I is fitted into the primary molded article P1 so as to be joined thereto until the intermediate mold 18 and the second mold (the fixed mold 16) are closed. At this time, the insert may be inserted into a predetermined position of the intermediate mold 18 including the primary molded article P1 by the insertion robot 51 in a state where the first mold (movable mold 14) and the intermediate mold 18 are opposed to each other after the first mold is opened as shown in fig. 4(c), or the insert I may be inserted into a predetermined position of the primary molded article P1 in a state where the intermediate mold 18 and the second mold (fixed mold 16) are opposed to each other after the intermediate mold 18 is rotated as shown in fig. 4 (d). Further, the insert I may be inserted from the side surface of the injection molding machine 11 into a predetermined position of the primary molded article P1 in a state where the intermediate mold 18 is rotated by 90 ° to face the direction orthogonal to the mold opening and closing direction a-a. Alternatively, after the primary molded product P1 is molded (after the previous finished product is removed), the insert 1 may be fitted into a predetermined position of the intermediate mold 18 or the second mold (fixed mold).

In the present embodiment, after the intermediate mold 18 is rotated as shown in fig. 4(d), the insert I is fitted into the primary molded product P1 or the intermediate mold 18 in a state of facing the second mold (the fixed mold 16). Then, as shown in fig. 4(e), the 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 toward a cavity C2 formed between the intermediate metal mold 18 and the second metal mold (the fixed metal mold 16) on the other side including the insert I. After 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 formed in the primary molding, and therefore, stress due to heat, pressure, or the like applied to the insert I during molding is smaller than that in the first embodiment. Therefore, the insert I is suitable for inserts I having poor heat resistance and pressure resistance. Further, when the insert I is fitted into the primary molded article P1 held by the intermediate mold 18, opposed to the second mold (the fixed mold 16), and injected from the second injection device 50, the insert I may be completed without complicating the runner structure of the primary molded mold. However, in the second embodiment, the coupling between the primary molded article P1 and the insert I is not strengthened by the injection from the first injection device 49, and becomes weak.

Next, a method of molding a composite of an insert and a resin material according to a third embodiment of the present invention shown in fig. 5 using the injection molding machine 11 for molding a composite shown in fig. 1 and 2 will be described. First, as shown in fig. 5 a, the first insert 1a is fitted into the first metal mold (movable metal mold 14) that is open or the intermediate metal mold 18 that faces the first metal mold (movable metal mold 14). Then, as shown in fig. 5 (b), the first mold (movable mold 14) and the intermediate mold 18 are closed, and the resin material M1 is injected from the second injection device 50 into the cavity C1 containing the fitted first insert Ia, thereby molding a primary molded product P1 made of the insert and the resin material. Then, as shown in fig. 5 (c), the first mold (movable mold 14) and the intermediate mold 18 are opened with the primary molded product P1 held in the intermediate mold 18.

Then, as shown in fig. 5(d), the intermediate mold 18 holding the primary molded product P1 is rotated and moved toward a position facing the fixed mold 16 as a second mold. Then, until the intermediate mold 18 and the fixed 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 fixed mold 16). Here, the second insert Ib is fitted into the intermediate die 18 holding the first molded product P1 in a state of facing the fixed die 16. Then, as shown in fig. 5(e), the resin material M2 is injected from the first injection device 49 into the cavity C2 including the primary molded article P1 and the second insert Ib formed by the closed mold. After the cooling of the molten resin in the chamber C2 is completed, the mold is opened again as shown in fig. 5(f), and the insert Ia and the insert Ib are integrated to obtain the composite P2 of the insert and the resin material by a robot (not shown). The insert Ia and the insert Ib are not limited to one insert, and may be a plurality of inserts.

Next, a method of molding a composite of an insert and a resin material according to a fourth embodiment of the present invention shown in fig. 6 using the injection molding machine 11 for molding a composite shown in fig. 1 and 2 will be described. First, as shown in fig. 6(a), the insert I is fitted into at least one of the first metal mold (movable metal mold 14) that is open or the intermediate metal mold 18 that faces the first metal mold (movable metal mold 14). In the fourth embodiment, the insert I is not limited thereto, and may be a flat-plate-shaped prepreg containing reinforcing fibers or a flat-plate-shaped sheet containing reinforcing fibers. Then, as shown in fig. 6 b, the first die (movable die 14) and the intermediate die 18 are closed, and the insert I is additionally processed (press-formed) in the cavity C1. At this time, heating and cooling for heating the first metal mold (movable metal mold 14) and the intermediate metal mold 18 in the first half and then cooling in the second half may be performed. Further, when the cavity C1 between the first die (movable die 14) and the intermediate die 18 is press-formed, secondary forming is desirably performed in parallel between the second die (fixed die) and the intermediate die 18, and the dies are desirably closed and locked in advance by the die opening and

closing units

19 and 20 and a locking device provided in the dies, not shown.

Then, as shown in fig. 6C, the core 53, which is a part of the cavity surface, of the first mold (movable mold 14) or the intermediate mold 18 is retreated (core retreated), thereby forming a cavity C1. Alternatively, the entire movable die 14 may be retracted to form the cavity C1 including the insert Ia. Then, the resin material M1 is injected from the second injection device 50 into the cavity C1 containing the insert Ia formed by press molding, and the primary molded product P1 made of the insert and the resin material is molded. Then, as shown in fig. 6(d), the first mold (movable mold 14) and the intermediate mold 18 are opened with the primary molded article P1 held in the intermediate mold 18. Then, as shown in fig. 6(e), the intermediate mold 18 holding the primary molded article P1 is rotated and moved to a position facing the second mold. Next, as shown in fig. 6(f), the intermediate mold 18 and the second mold (the fixed mold 16) are closed, and the resin material M2 is injected from the first injection device 49 into the cavity C2 including the primary molded article P1 formed by the closing. Then, the insert-resin material composite P2 is molded, the mold is opened as shown in fig. 6(g), and the insert-resin material composite P2 is taken out by a robot (not shown).

The addition process to the insert I according to the fourth embodiment may be performed in a state where the insert I is inserted and opened. The treatment in this case includes coating of the insert I, coating for improving the bonding state between the insert I and the resin material, preheating of the insert I, and drilling of the insert I. Further, an additional process such as painting may be performed in the cavity C1 formed by fitting the insert I into the mold and then closing the mold. Alternatively, the insert I may be formed by inserting a reinforcing fiber sheet containing reinforcing fibers, a binder, and the like as the insert I, and injecting or injecting a low-viscosity molten resin into the sheet in the cavity C1 to impregnate the reinforcing fiber sheet with the resin material. In addition, the material containing the reinforcing fibers may be only reinforcing fibers.

In addition, the first to fourth embodiments can be used in appropriate combinations within practicable ranges. The number of inserts I to be inserted (inserted and placed) into one of the chambers C1 and C2 is not limited to the case of molding the first molded product, and the case of molding a composite (finished product) of the inserts and the resin material. The number of cavities C1 and C2 (the number of completed products of the metal mold) of the metal mold is not limited. Further, the first mold of the injection molding machine in which the intermediate member to which the intermediate mold is attached is disposed rotatably about the axis orthogonal to the mold opening direction between the first tray to which the first mold is attached and the second tray to which the second mold is attached may be the fixed mold 16, the primary molded article P1 may be molded between the fixed mold 16 and the intermediate mold 18, the second mold may be the movable mold 14, and the secondary molded article may be molded between the movable mold 14 and the intermediate mold 18, thereby forming the composite body P2 of the insert and the resin material. The injection molding machine 11 of the present invention can be used for molding of multi-color molded articles and single-color molded articles without being fitted, as a matter of course, by replacing the mold.

Next, description will be given of matters when any one of the first to fourth embodiments is used by a combination of injection molding of an insert of a metal material and a reinforcing fiber resin. As described in the background section, in order to reduce the weight of an automobile, it is desired to use a resin material, which is called a multi-material, including a metal material such as high-strength steel, stainless steel, aluminum, or magnesium, and a reinforcing fiber such as a carbon fiber or a glass fiber, in a composite. In the present invention, the metal insert I includes an insert having a portion made of a material other than a metal material.

First, as shown in fig. 7, an elongated insert I made of a metal material and provided with an engaging portion 61 such as a bolt hole at least at one end is prepared. The insert I of the metal material is thinner than an insert of a finished part made of only metal, and does not have strength required for automobile parts or the like alone. In fig. 7, the insert I made of a metal material is a linear member, but is not limited in shape, for example, having a curved portion, a branched portion, or a different thickness. Then, in order to improve the bondability with the reinforcing fiber resins M1 and M2, the metal surface is subjected to surface treatment such as blast treatment, laser treatment, plasma treatment, and chemical treatment (chemical etching) before the composite is molded. In addition, since the composite P2 composed of a metal material and a reinforcing fiber resin may cause galvanic corrosion or the like of the metal portion due to the potential difference, it is preferable to coat the surface of the metal material to prevent this. In the first to fourth embodiments, the resin materials M1 and M2 containing reinforcing fibers for injection molding are preferably thermoplastic resins in terms of cost and molding time. In many cases, these materials are poor in flowability at the time of injection, and it is preferable to use a mold which can be heated and cooled for the mold, or to perform injection compression molding which is one type of injection molding. The resin materials M1 and M2 containing reinforcing fibers of the first injection device 49 and the second injection device 50 are preferably the same resin materials when they are covered from both sides as in the first embodiment. However, when the surface layer is injected from the second injection device 50 onto the surface of the primary molded article containing the reinforcing fiber resin and the secondary molding is performed, the recycled material may be used for the primary molding to expose the resin material M1 of the fibers on the surface, and the resin material M2 containing no reinforcing fibers or the resin material M2 containing the reinforcing fibers in a lower amount than the primary molding may be used for the secondary molding.

The composite of the metal material and the reinforcing fiber resin molded by the injection molding machine 11 may be subjected to a process for improving the dimensional accuracy at a time when the cooling shrinkage, warpage, or the like is completely eliminated. Specifically, the bolt holes and the engaging portions of the metal portions may be formed not initially but by a process after the composite P2 (finished product) of the insert and the resin material is molded. In many cases, the engaging bolt hole and the engaging portion can be formed in a more accurate positional relationship than the engaging bolt hole and the engaging portion formed in the metal material before the fitting.

The present invention is not limited to the above-described embodiments, and those skilled in the art can use the present invention by changing or combining the parts of the above-described embodiments based on the gist of the present invention. The mold clamping device 13 may be a vertical injection molding machine that opens and closes a mold in the longitudinal direction. In the case of a vertical injection molding machine, since an insert is fitted into the upper surface of a mold, the fitting operation itself is often facilitated.

Claims

1. A method of molding a composite of an insert and a resin material, the insert and the resin material being integrated in a cavity of a mold, the method comprising the steps of,

an injection molding machine is used, wherein an intermediate member having an intermediate mold is rotatably disposed between a first tray having a first mold attached thereto and a second tray having a second mold attached thereto about an axis orthogonal to a mold opening direction,

closing the opened first metal mold and the intermediate metal mold,

a resin material is injected into the cavity formed by the closed mold to form a primary molded article,

the intermediate mold holding the primary molded article is rotated and moved toward a position facing the second mold,

in any step until the intermediate mold and the second mold are closed to form a cavity including a primary molded article, an insert is fitted into at least one of the first mold, the intermediate mold, the second mold, and the primary molded article,

injecting a resin material into a cavity containing the primary molded product.

2. A method of molding a composite of an insert and a resin material, the insert and the resin material being integrated in a cavity of a mold, the method comprising the steps of,

an insert is fitted into a first metal mold opened or an intermediate metal mold opposed to the first metal mold,

the first metal mold and the intermediate metal mold are closed,

a resin material is injected into a cavity including one side of the embedded insert to form a primary molded article composed of the insert and the resin material,

opening the first mold and the intermediate mold while holding the primary molded article in the intermediate mold,

closing the intermediate metal mold and the second metal mold,

injecting a resin material into the other cavity of the insert including the primary molded article formed by the mold closing.

3. A method of molding a composite of an insert and a resin material, the insert and the resin material being integrated in a cavity of a mold, the method comprising the steps of,

the first metal mold and the intermediate metal mold are closed,

injecting a resin material into a cavity between the first metal mold and the intermediate metal mold,

opening the first mold and the intermediate mold while holding the primary molded article made of the resin material in the intermediate mold,

the intermediate member and the intermediate mold holding the primary molded article are rotationally moved toward a position facing the second mold,

inserting a second insert into at least one of the primary molded product, the intermediate metal mold, and the second metal mold until the intermediate metal mold and the second metal mold are closed,

a resin material is injected into a cavity formed by the mold closing and including the primary molded article and the second insert.

4. A method of molding a composite of an insert and a resin material, the insert and the resin material being integrated in a cavity of a mold, the method comprising the steps of,

a first insert is fitted into the first metal mold opened or an intermediate metal mold opposed to the first metal mold,

the first metal mold and the intermediate metal mold are closed,

a resin material is injected into a cavity containing the embedded first insert to form a primary molded article composed of the insert and the resin material,

a resin material is injected into a cavity formed by the closed mold and including the primary molded article and the second insert.

5. A method of molding a composite of an insert and a resin material, the insert and the resin material being integrated in a cavity of a mold, the method comprising the steps of,

additionally processing the insert while keeping the mold opened or after closing the first metal mold and the intermediate metal mold,

a resin material is injected into a cavity containing the insert which is further subjected to additional processing to mold a primary molded article composed of the insert and the resin material,

closing the intermediate metal mold and the second metal mold,

injecting a resin material into a cavity containing the primary molded product formed by the closed mold.

6. The method of forming a composite of an insert and a resin material as set forth in any one of claims 1 to 5,

the insert is made of metal material or material containing reinforced fiber.

7. An apparatus for molding a composite of an insert and a resin material, comprising:

an injection molding machine including a metal mold used in the method for molding the composite of the insert and the resin material according to any one of claims 1 to 6; and

and a robot disposed at a side of the injection molding machine and configured to insert the insert into a predetermined position of the mold or the primary molded article.