JP2001239550A - Method and apparatus for manufacturing injection- molded article having pores - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and apparatus for continuously manufacturing an injection-molded article having pores, especially, an optical connector part with good productivity at a low cost. SOLUTION: A process for inserting a long wire material 4 in the cavity of a mold 1, which has at least one cavity 2 regulating a product outer shape, under tension and injecting a flowable material in the cavity and a process for intermittently moving the wire material are successively repeated to manufacture a series of intermediate articles wherein a large number of injection-molded articles are fixed to the wire material and, thereafter, the wire material of the intermediate articles is axially pulled to be elastically deformed so that the diameter of the wire material is reduced and the wire material is pulled out of the injection molded articles. As the wire material, a heat-resistant metal wire high in elastic limit, especially, a wire comprising an Ni-Ti ultraelastic alloy is used and, as the flowable material, various materials such as ceramic paste, a synthetic resin, a metal, an amorphous alloy containing 50 volume % or more of the amorphous phase or the like can be used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing an injection-molded article having pores, and more particularly, to continuously injection-molding a large number of injection-molded articles on an intermittently moving wire. Thereafter, the wire is pulled in the axial direction to be elastically deformed so that the wire diameter becomes thinner and withdrawn, and the injection molding having pores, in particular, a technology relating to a technology for continuously manufacturing optical connector parts (ferrules, capillaries, etc.) and the like. It is.

[0002]

2. Description of the Related Art A typical example of a molded article having pores and requiring high dimensional accuracy is a ferrule for an optical connector or a part used for optical communication such as a capillary. Hereinafter, description will be given with reference to the accompanying drawings. FIG. 11 shows a capillary section 1 in an optical connector.
01 and the flange portion 102 show an integrated ferrule 100. That is, the ferrule 100 includes a capillary portion 101 in which a small-diameter through hole 103 for inserting the optical fiber 107 (or an optical fiber) is formed along the central axis, and the optical fiber core 1 along the central axis.
06 (in which an outer jacket is attached to the outer periphery of an optical fiber) A flange portion 102 in which a large-diameter through hole 104 for insertion is formed
And a small-diameter through-hole 103 and a large-diameter through-hole 104.
Are connected via a tapered diameter portion 105. The connection of the pair of optical fibers 107 is performed by dividing each ferrule 100 into which they are inserted and joined.
This is performed by inserting the ferrules 100 from both ends and abutting the ends of the ferrules 100, whereby the ends of the optical fibers 107 are abutted and connected with the axes thereof aligned. On the other hand, FIG. 12 shows an optical connector ferrule 100a in which a capillary 101a of an optical connector and a flange 102a are separate bodies.

[0003] The diameter of the pores through which the optical fiber passes varies depending on the type. For example, a capillary (ferrule) called an SC type has pores of 0.126 mm in diameter and 10 mm in depth. Conventionally, ferrules are made of ceramics such as zirconia. In forming the pores of the ceramic ferrule, a ferrule having small pores is injection-molded in advance, and after firing, the ferrule is finished to a regular size by wire wrapping. Further, the ceramic ferrule is manufactured through many steps such as outer diameter processing and polishing in addition to inner diameter processing. Therefore, the manufacturing process is long and the cost is forced to increase.

As a method for solving the above problems, the present applicant has already developed a ferrule for an optical connector by a combination of a technique based on a conventional mold casting method and an amorphous alloy showing a glass transition region. Even if it is a molded product having such fine pores or a molded product with a complicated shape, an amorphous alloy molded product that satisfies the predetermined shape, dimensional accuracy, and surface quality can be manufactured with high productivity in a single process. A method has been developed and a patent application has been filed (JP-A-10-186176). The method for producing an amorphous alloy molded article having pores disclosed herein basically involves a high-speed melt of a material capable of forming an amorphous alloy in a mold cavity in which a core pin is set. And casting, and then the core pin is pulled out of the cast material to form pores.

[0005]

Normally, in order to obtain a cast product having pores, a core pin to which a release agent is uniformly applied must be used. However, since the release agent is used, when the molten metal touches the core pin, the release agent evaporates at a stretch, so that air bubbles and defects may remain in the cast molded product. Furthermore, since the direction in which the release agent evaporates cannot always be controlled uniformly, there has been a problem that the dimensional accuracy of the pores cannot be made high.
In addition, in order to obtain a high-precision cast molded product, if casting is performed with a higher injection pressure during casting, there is almost no gap between the core pin for forming pores and the cast material. This causes a problem that the core pin does not come off, a problem that the pin is bent, a surface of the pin is damaged or damaged. Further, there is a problem that the concentricity of the pores of the obtained product is shifted. Moreover,
Since this core pin is made of a cemented carbide and is expensive, there is a problem that the pin cannot be used repeatedly due to scratching or breakage of the pin, resulting in an increase in manufacturing cost. Such a problem is not a problem peculiar to the ferrule for an optical connector or a capillary, but a problem common to the die casting of a molded product having pores.

Accordingly, a basic object of the present invention is to eliminate the above-mentioned various problems caused by the use of a core pin,
An object of the present invention is to provide a method and an apparatus capable of continuously producing an injection molded product having pores at a low cost with good productivity. Further, a more specific object of the present invention is to provide a method and an apparatus capable of forming an amorphous alloy having long and narrow holes by a simple process and with a predetermined shape, high dimensional accuracy and surface quality. It is another object of the present invention to provide an inexpensive amorphous alloy molded product having pores excellent in durability, strength, impact resistance and the like, particularly an optical communication component such as a ferrule for an optical connector or a capillary.

[0007]

In order to achieve the above object, according to the present invention, at least one device for regulating the outer shape of a product is provided.
A long wire is stretched in a state of being inserted into each cavity of a mold having two cavities, and a step of injecting and filling a fluid material into the cavity and a step of intermittently moving the wire are sequentially repeated, Producing a series of intermediate products in which a number of injection molded products are fixed to the wire; and pulling the intermediate material wires in the axial direction to deform them, and removing the wires from the injection molded products. Provided is a method for producing an injection-molded article having pores as described below. As the fluid material, ceramic paste, synthetic resin,
Various materials such as a metal or an amorphous alloy containing an amorphous phase having at least a volume fraction of 50% or more can be used.

Further, according to the present invention, a mold having at least one cavity for regulating the outer shape of a product; a long wire stretched while being inserted into each cavity of the mold; Means for stretching and intermittently moving; an injection means for injecting and filling a fluid material into the cavity of the mold; an intermediate product obtained in a state where the injection molded article is fixed to the wire after injection molding. Means for applying a tensile load to the wire material in the axial direction to withdraw the wire material from the injection-molded product.

In a preferred aspect, a centering mechanism is further provided in one or both of the front and rear of the die in the wire moving direction. The mold has at least one cavity opened on the wire movement direction side, and has a mold part provided with ejector means capable of projecting in the wire movement direction in the cavity, and a wire movement of the mold part. Arranged on the direction side,
In addition, it is preferable to include a split part having the wire insertion part as a parting surface. The split mold part may have a cavity opened on the opposite side to the wire moving direction. By the method and apparatus as described above, injection molded articles having pores,
In particular, an amorphous alloy molded product, and further a ferrule or capillary for an optical connector can be manufactured with high productivity.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION The production of an injection molded article having pores according to the present invention does not use a core pin as in the prior art, but uses a mold having at least one cavity for regulating the outer shape of the product. A long wire is stretched in a state inserted into the cavity, and a step of injecting and filling a flowable material into the cavity and a step of intermittently moving the wire are sequentially repeated, and a large number of injection molded articles are formed on the wire. After manufacturing a series of intermediate products to which is fixed, the wire of the intermediate product is pulled in the axial direction to be deformed, and the wire is extracted from the injection-molded product, and a conventional core pin is used. Instead of a batch method, an injection molded product having pores can be manufactured continuously. Since tension is applied to the wire during the injection process, even if the flowable material flows from the side of the wire or causes turbulence in the mold, the wire will not fail. It is possible to produce an injection molded product with high precision of pores without bending easily. Also, at the time of drawing, since the wire itself deforms, a minute gap is formed between the wire and the injection molded product, and the wire can be pulled out,
Pores are formed. The cross-sectional shape of the pore can be arbitrarily changed by changing the cross-sectional shape of the wire used.

[0011] The difficulty in pulling out a wire from an injection-molded article and the above-mentioned problems associated therewith can be solved by improving the drawability of the wire. As a method for improving the pullability of the wire after the injection molding, the following method is preferable. In the following, the wire is described as a wire. (1) Elastic wire, superelastic wire method This is a method of using a wire having a high elasticity limit as a wire (wire). By this, when the wire is pulled out from the injection molded product, the wire is elastically deformed in the drawing direction, so that the wire becomes thinner with respect to the pores of the injection molded product, and the clearance between the wire and the injection molded product is reduced. Since the wire is secured, the wire can be pulled out, and pores having a cross-sectional shape of the wire can be formed in the injection molded product. As the wire, for example, a spring material, a high-tensile steel material, a superelastic material (Ni-Ti superelastic material or the like) can be used.

(2) Surface coating and surface treatment wire method A method of coating a film which is easy to peel off on the surface of the wire so that the wire is easily released from the injection molded product, or a wire having a surface film adhered in production. It is a method of utilizing. As a result, when the wire is pulled out of the injection molded product, the surface coating of the wire is in close contact with the cast material, so that the surface coating is partially or entirely peeled off from the wire and only the wire is pulled out. Pores having a cross-sectional shape can be formed in the injection molded product. The surface coating of the wire is made of a material such as an oxide such as TiO ₂ , a nitride such as TiN, or a carbide such as TiC by physical vapor deposition (PVD) or chemical vapor deposition (CVD). By electroplating of metal or the like, electroless plating, hot-dip plating or the like. Further, the surface coating of the wire, if the wire is an active metal material, without performing any special treatment in the manufacturing process, an oxide containing a wire constituent element as a scale,
It is also possible to use a film in which a film such as nitride or carbide remains as it is. The thickness of the film is about 0.5 to 100 from the viewpoint of the peelability of the film and the pull-out property of the wire.
It is preferably about μm. In this method, various materials can be used as the wire material, and among them, a Ti-based alloy having excellent heat resistance and the like is preferable. The above methods (1) and (2) can be adopted in combination. In addition, the thickness of the wire can be arbitrarily changed according to a desired pore diameter, but is generally set in the range of φ0.025 to 1 mm in the case of manufacturing an optical connector part.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described more specifically with reference to the embodiments shown in the accompanying drawings. In the following, an example in which the method of the present invention is applied to the manufacture of a ferrule (capillary) for an optical connector will be described, but it goes without saying that the present invention is not limited to this. Examples of the fluid material include metals, amorphous alloys containing an amorphous phase having a volume ratio of at least 50%, ceramic pastes such as zirconia and alumina, and synthetic resins such as fiber-reinforced thermotropic liquid crystalline polyester. For example, a case where an alloy is used as a ferrule material will be described. Further, in the following, a case where a wire having a high elasticity limit is used will be described as an example.

FIGS. 1 and 2 show a schematic configuration of an embodiment of a method and an apparatus for producing an injection molded article having pores according to the method of the present invention. In FIGS. 1 and 2, reference numeral 1 denotes a split mold having two product-shaped cavities 2, and a gate 3 communicating with the cavities 2 is formed at a lower portion thereof. On the other hand, reference numeral 4 denotes a wire (wire) made of a material having a high elasticity limit. The mold 1 can be made of copper, a copper alloy, a cemented carbide, and other metal materials.
A flow path through which a cooling medium such as a liquid or a gas or a heating medium flows may be provided. On the other hand, the wire 4 is made of a material having a high elasticity limit, such as a spring material, a high-tensile steel material, or a superelastic material. The wire 4 is supplied from a wire supply reel 5 and stretches between a wire take-up reel (not shown) while being inserted through each cavity 2 of the mold 1, and a certain tension is applied by a tension reel 6. It is set as follows.

As shown in FIGS. 2 and 3, the mold 1 has at least one cavity 2 opened on the wire moving direction side, and ejector means (FIG. 2) protruding into the cavity in the wire moving direction. (Not shown)
And split mold parts 1b and 1c which are arranged on the side of the mold part 1a in the wire moving direction and which can be separated to the left and right with the wire insertion part as a parting surface. An injection sleeve 7 is provided below the mold 1 so as to be able to move up and down toward the gate 3 of the mold 1. An injection plunger 8 is slidably disposed in the injection sleeve 7, and is moved up and down by a hydraulic cylinder (or pneumatic cylinder) (not shown). A high-frequency induction coil 9 is provided around the upper portion of the injection sleeve 7 as a heating source. As a heating source, any means such as resistance heating can be adopted in addition to high-frequency induction heating. The materials of the injection sleeve 7 and the injection plunger 8 include:
Heat resistant materials such as ceramics and heat resistant coating metal materials are preferred. Reference numeral 10 denotes a fixed board. In addition,
In order to prevent the formation of an oxide film on the molten metal, the entire apparatus is placed in a vacuum or in an inert gas atmosphere such as Ar gas,
Alternatively, it is preferable to flow an inert gas at least between the mold 1 and the injection sleeve 7.

In manufacturing a capillary, first, the alloy raw material A is loaded in a state where the injection sleeve 7 is separated below the mold 1. As a method for loading the alloy raw material A, any method can be adopted. For example, as shown in FIG. 2, a raw material supply sleeve 11 is attached to the side of the injection sleeve, and the raw material is sequentially injected by the raw material supply plunger 12 into the injection sleeve 7.
The method of pushing in is advantageous. Raw material supply sleeve 11
The raw material is supplied to the raw material supply sleeve 11 by incorporating the raw material storage magazine so that the raw material is dropped from the raw material storage magazine to the raw material supply sleeve 11 one by one.
Alternatively, a plurality of such material storage magazines may be incorporated into a turntable in a cassette system, and when the material in one material storage magazine is exhausted, the turntable is rotated by a predetermined angle, and the next material storage magazine is moved to a predetermined position. Such a structure can be adopted as appropriate.

Next, the high frequency induction coil 9 is excited to rapidly heat the alloy raw material A. After detecting the temperature of the molten metal to confirm whether or not the alloy raw material A has melted, the high-frequency induction coil 9 is demagnetized, and then the upper end of the injection sleeve 7 is brought into contact with the fixed plate recess 10 a around the gate 3 of the mold 1. Until they come into contact with each other, the injection sleeve 7 and the injection plunger 8 are raised synchronously, and the injection plunger 8 is further raised rapidly to inject the molten metal from the gate 3 of the mold 1. The injected molten metal is injected into the cavity 2, pressurized, and rapidly solidified. At this time, by appropriately setting the injection temperature, injection speed, and the like,
A cooling rate of 10 ³ K / s or more can be obtained. Thereafter, the injection sleeve 7 and the injection plunger 8 are lowered,
The next raw material loading is performed. On the other hand, after the mold temperature is cooled to a temperature equal to or lower than the melting point of the molten metal (or a glass transition temperature (Tg) or lower when an amorphous alloy material is used), the split mold portions 1b and 1c of the mold 1 are cooled. The injection molded product is separated into right and left parts by an ejecting mechanism as described later, and the wire 4
Is moved by a predetermined distance. In this way, the injection filling process of the mold 1 into the cavity 2 and the intermittent moving process of the wire 4 are sequentially repeated to produce a series of intermediate products in which a large number of injection molded products B (capillaries) are fixed to the wire 4.

Next, after cutting the wire 4 as an intermediate product, as a finishing step, the wire 4 is pulled in the axial direction to be elastically deformed so as to reduce the wire diameter, and the wire 4 is removed from the injection molded product B (capillary). After pulling out, performing cone hole processing, outer diameter finishing, and edge finishing, press-fitting flange, optical fiber insertion bonding, PC polishing (convex spherical polishing)
Perform In addition, the cone hole processing is performed on one end surface of the capillary (flange press-fit side) to facilitate insertion of the optical fiber.
To grind the opening of the hole into a conical shape. The end finishing refers to a chamfering process for rounding both end edges of the capillary. Note that the outer diameter finishing (outer diameter polishing) is not required to be performed when the capillary is manufactured from the amorphous alloy, but may be performed as necessary. Depending on the raw material used, the pores of the capillary may be subjected to wire wrapping, if necessary.

In the case of the mold 1, when the product part cavity is composed of two mold parts, burrs and the like are generated on the mold parting surface of the product part. Therefore, it is preferable that the cavity of the product portion where the burr or the like is not desired to be formed is formed by one mold. For example, when manufacturing a capillary of an optical connector component, as shown in FIG. 3, the cavity of the capillary portion 2a is constituted by one mold portion 1a, and the mold portion on the moving direction side of the wire 4 can be divided into right and left. Two split mold parts 1b and 1
(The eject mechanism in the mold will be described later, and is omitted). Reference numeral 13 denotes a wire insertion hole formed in the mold portion 1a, and 14 denotes a split mold portion 1.
This is a wire insertion hole formed in the parting surfaces b and 1c. Further, when manufacturing a ferrule of an optical connector part in which the capillary portion and the flange portion are integrated, as shown in FIG. 4, the capillary portion 2a which requires roundness and cylindricity is required.
Is composed of one mold part 1a, while 1
The flange portion 2b, which is difficult to eject in the moving direction of the wire 4 with one mold, includes two split mold portions 1b and 1c that can be divided into right and left.

Next, the eject mechanism in the mold will be described. In the case of a mold as shown in FIG. 3, for example, an ejector pin is also used for a wire insertion portion of the mold portion 1a in which the cavity of the capillary portion 2a is formed. That is, as shown in FIG. 5, a wire insertion hole 13 is formed in the ejector pin 15a itself so that the ejector pin 15a can protrude into the cavity of the capillary portion 2a. Alternatively, FIG.
As shown in (1), the product portion or the runner portion in the mold is ejected by the ejector pin 15b.

Since the wire is under tension, a considerable degree of concentricity can be obtained, and some injection molded products do not require much dimensional accuracy. However, parts for optical connectors that require higher dimensional accuracy,
For example, in the case of a capillary, it is necessary that the concentricity of the wire with respect to the cavity of the capillary part in the mold be 1 μm or less. For this reason, it is preferable to provide a centering mechanism on the wire. Note that the wire insertion hole 13 of the mold 1 requires a clearance of several μm for the movement of the wire 4. Therefore, the wire is centered outside the mold.

An example of the alignment method will be described with reference to the drawings. FIG. 7 shows an alignment method when the wire 4 is made of a magnetic material. That is, in the case of this example, a plurality of (four in the illustrated example) electromagnets 16 are arranged around the wire 4 in the vicinity of the mold part 1a, and the wire 4 is always in a fixed positional relationship with the mold part 1a. Is configured to be inserted through the wire insertion hole 13.

FIG. 8 shows a centering method using a piezoelectric element. The centering device 17 includes a pair of piezoelectric elements 18a and 18b attached to fixed portions 17a and 17b arranged at right angles, a substantially L-shaped movable member 19a operated by the piezoelectric elements, and Movable member 1 movably disposed in the member 19a toward the corner thereof
9b. The movable member 19b presses the wire 4 against the corner of the movable member 19a by a spring, an electromagnet, or the like.
The wire 4 is positioned in the X and Y directions by b. Note that any of the above-described centering mechanisms can be provided not on the mold part 1a side but on the split mold parts 1b and 1c or on both sides thereof. However, in the case of the capillary for an optical connector, since the concentricity of the hole at the tip (left side in the drawing) is important, it is preferable to arrange the alignment mechanism at least on the mold part 1a side.

FIGS. 9 and 10 show examples of other alignment methods. As shown in FIG. 9, when the wire insertion hole 13 of the mold part 1 a is tapered so as to expand toward the cavity 2, the flow direction of the molten metal at the time of injection is concentric with the wire insertion hole 13. Therefore, the wire 4 is automatically aligned with the cavity. On the other hand, FIG. 10 shows an example of the centering method on the wire moving direction side. As shown in FIG. 10, when the injection molded product B taken out from the mold 1 after the injection is located on the same reference plane as the cavity 2 in the mold 1, for example, on the fixed platen 10, the injection molded product B (The left side in the drawing) is used to position the wire in the wire moving direction with respect to the cavity 2 of the mold 1.

The injection material used in the method of the present invention includes:
Any material used in general casting can be used, and is not limited to a specific material, but is preferably a substantially amorphous material containing an amorphous phase having at least a volume fraction of 50% or more. Alloys can be suitably used. More preferably, an amorphous alloy having a composition represented by any one of the following general formulas (1) to (6) can be suitably used. Formula _{^{(1): M 1 a M}} 2 b Ln c M 3 d M 4 e M 5 f However, one or two elements M ¹ is selected from Zr and Hf, M ² is Ni, Cu, Fe , Co, Mn, Nb, T
at least one element selected from the group consisting of i, V, Cr, Zn, Al and Ga; Ln is Y, La, Ce, N
at least one element selected from the group consisting of d, Sm, Gd, Tb, Dy, Ho, Yb, and Mm (mish metal which is an aggregate of rare earth elements); M ³ is Be, B,
At least one element selected from the group consisting of C, N and O; M ⁴ is at least one element selected from the group consisting of Ta, W and Mo; M ⁵ is Au, Pt, Pd and A;
at least one element selected from the group consisting of g, a,
b, c, d, e and f are each atomic%, and 25 ≦ a ≦
85, 15 ≦ b ≦ 75, 0 ≦ c ≦ 30, 0 ≦ d ≦ 30,
0 ≦ e ≦ 15 and 0 ≦ f ≦ 15.

The above amorphous alloy has the following general formula (1-a)
To (1-p). General formula (1-a): M ¹ _a M ² _b This amorphous alloy has a large negative enthalpy of mixing and good amorphous forming ability because the M ² element coexists with Zr or Hf. Formula ^{(1-b): M 1} a M 2 b Ln c , as in this amorphous alloy, the thermal stability of the amorphous by adding a rare earth element to the alloy of the formula (1-a) is improves.

The general formula ^{(1-c): M 1} a M 2 b M 3 d general formula ^{(1-d): M 1} a M 2 b Ln c M 3 d like these amorphous alloys, the atomic Element M with small radius
³ By filling the gaps in the amorphous structure with (Be, B, C, N, O), the structure is stabilized and the ability to form an amorphous structure is improved.

The general formula ^{(1-e): M 1} a M 2 b M 4 e general formula ^{(1-f): M 1} a M 2 b Ln c M 4 e general formula ^{(1-g): M 1} a _{^{M 2 b M 3 d M 4}} e general formula ^{(1-h): M 1} a M 2 b Ln c M 3 d M 4 e like these amorphous alloys, refractory metal M ⁴ (Ta,
When (W, Mo) is added, heat resistance and corrosion resistance are improved without affecting the ability to form an amorphous phase.

The general formula ^{(1-i): M 1} a M 2 b M 5 f general formula ^{(1-j): M 1} a M 2 b Ln c M 5 f general formula ^{(1-k): M 1} a _{^{M 2 b M 3 d M 5}} f general formula ^{(1-l): M 1} a M 2 b Ln c M 3 d M 5 f general formula ^{(1-m): M 1} a M 2 b M 4 e M 5 _f general formula ^{(1-n): M 1} a M 2 b Ln c M 4 e M 5 f general formula ^{(1-o): M 1} a M 2 b M 3 d M 4 e M 5 f general formula (1 _{^{-p): M 1 a M 2}} b Ln c M 3 d M 4 e M 5 f these noble metals ^{M 5 (Au, Pt, Pd} , when the amorphous alloy containing Ag), and crystallization occurred Does not become brittle.

The general formula _{(2): Al 100-ghi} Ln g M 6 h M 3 i However, Ln is Y, La, Ce, Nd, Sm, Gd, T
at least one element selected from the group consisting of b, Dy, Ho, Yb, and Mm; M ⁶ is Ti, V, Cr, Mn,
Fe, Co, Ni, Cu, Zr, Nb, Mo, Hf, T
at least one element selected from the group consisting of a and W, M ³ is at least one element selected from the group consisting of Be, B, C, N, and O; g, h, and i are each atomic%; 30 ≦ g ≦ 90, 0 <h ≦ 55, 0 ≦ i ≦ 10
It is.

The above amorphous alloy has the following general formula (2-a)
And (2-b) amorphous alloys. Formula _{(2-a): Al 100} -gh Ln g M 6 h This amorphous alloy, mixing enthalpy is large in negative, amorphous forming ability is good. Formula _{(2-b): Al 100} -ghi Ln g M 6 h M 3 i In this amorphous alloy, small elements M ³ atomic radius
By filling gaps in the amorphous structure with (Be, B, C, N, O), the structure is stabilized, and the ability to form an amorphous structure is improved.

Formula (3): Mg _100-p M ⁷ _p where M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, and p is atomic% and 5 ≦ p ≦
60. This amorphous alloy has a large negative enthalpy of mixing and a good amorphous forming ability.

Formula (4): Mg _100-qr M ⁷ _q M ⁸ _r where M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, and M ⁸ is Al, Si and At least one element selected from the group consisting of Ca, q
And r are each atomic%, 1 ≦ q ≦ 35, 1 ≦ r ≦ 2
5 As in this amorphous alloy, the general formula (3)
Element M ⁸ (Al, S
By filling gaps in the amorphous structure with (i, Ca), the structure is stabilized, and the ability to form an amorphous phase is improved.

General formula (5): Mg _100-qs M ⁷ _q M ⁹ _s General formula (6): Mg _100-qrs M ⁷ _q M ⁸ _r M ⁹ _s where M ⁷ is Cu, Ni, Sn and Zn at least one element selected from the group consisting of at least one element M ⁸ is Al, selected from the group consisting of Si and Ca, M
⁹ is at least one element selected from the group consisting of Y, La, Ce, Nd, Sm and Mm, q, r and s are each atomic%, and 1 ≦ q ≦ 35, 1 ≦ r ≦ 25, 3 ≦ s ≦
25. Like these amorphous alloys, by adding a rare earth element to the alloys of the general formulas (3) and (4), the thermal stability of the amorphous is improved.

Among the above-mentioned amorphous alloys, the Zr-TM-Al system and the Hf-TM-Al system (TM: TM) having an extremely wide temperature difference between the glass transition temperature (Tg) and the crystallization temperature (Tx).
Transition metal) amorphous alloys have high strength and high corrosion resistance and have a supercooled liquid region (glass transition region) ΔTx = Tx−
The Tg is 30K or more, particularly the Zr-TM-Al-based amorphous alloy is as wide as 60K or more. In this temperature range, due to viscous flow, very good workability is exhibited even at a low stress of several tens MPa or less. In addition, the amorphous bulk material can be obtained even by a casting method having a cooling rate of about several tens of K / s. These alloys produce an amorphous material and at the same time reproduce the mold shape and dimensions very faithfully, either by die casting from the melt or by viscous flow forming utilizing the glass transition region.

These Zr-TM- used in the present invention
The Al-based and Hf-TM-Al-based amorphous alloys have a very large range of ΔTx, depending on the alloy composition and the measurement method. For example, Zr ₆₀ Al ₁₅ Co _2.5 Ni _7.5
ΔT of Cu ₁₅ alloy (Tg: 652K, Tx: 768K)
x is as wide as 116K. It has very good oxidation resistance, and is hardly oxidized even when heated to a high temperature up to Tg in air. Vickers hardness (H) from room temperature to around Tg
v): 460 (DPN), tensile strength: 1,600MP
a, The bending strength reaches 3,000 MPa. Thermal expansion coefficient α
Is as small as 1 × 10 ⁻⁵ / K from room temperature to around Tg, the Young's modulus is 91 GPa, and the elastic limit during compression exceeds 4 to 5%. Higher toughness, 60-70 Charpy impact value
It shows kJ / m ² . When the glass transition region is heated while exhibiting such a very high strength characteristic, the flow stress decreases to about 10 MPa. For this reason, it is a feature of the present alloy that it is extremely easy to process and can be formed into minute parts and high-precision parts having low stress and complicated shapes. Moreover, the processed (deformed) surface has extremely high smoothness due to the characteristics as a so-called glass (amorphous), and substantially no steps such as a step in which a slip band appears on the surface as when a crystalline alloy is deformed. have.

Generally, when an amorphous alloy is heated to the glass transition region, crystallization starts due to holding for a long time. However, an alloy having a wide ΔTx such as the present alloy has a stable amorphous phase and a temperature within ΔTx. If no is selected, no crystal is generated until about 2 hours, and there is no need to worry about crystallization in ordinary molding. In addition, the alloy exerts this property even when solidifying from the molten metal. Generally, rapid cooling is required for the production of an amorphous alloy. However, the present alloy can easily obtain a bulk material composed of an amorphous single phase from a molten metal by cooling at a cooling rate of about 10 K / s. The solidified surface is still extremely smooth, and has a transferability that faithfully reproduces even micron-order polishing scratches on the mold surface. Therefore, if this alloy is applied as an injection material, if the surface of the mold has a surface quality that satisfies the required characteristics of the molded product, the surface characteristics of the mold are reproduced as it is, and the process of dimensional adjustment and surface roughness adjustment Can be omitted or shortened.

As described above, relatively low hardness, high tensile strength and high bending strength, relatively low Young's modulus, high elastic limit, high impact resistance, high abrasion resistance, surface smoothness, high precision The feature having both castability is suitable as a material for molded products in various fields such as ferrules, capillaries, sleeves, V-groove substrates, and precision parts such as gears and micromachines of optical connectors. In addition, since amorphous alloys have high-precision castability and workability, and have excellent transferability that can faithfully reproduce the cavity shape of the mold, by appropriately manufacturing the mold, By the die casting method, a molded product satisfying a predetermined shape, dimensional accuracy, and surface quality can be manufactured in a single process with good mass productivity.

The materials used for the production of the molded article made of an amorphous alloy to which the present invention is applied include, in addition to the above-mentioned amorphous alloy, JP-A-10-186176 and JP-A-1
Various known amorphous alloys such as the amorphous alloys described in JP-A No. 0-31923, JP-A-11-104281 and JP-A-11-189855 can be used.

The metal materials used in the production of the injection molded article of the present invention include the above-mentioned amorphous alloys, Al-based alloys, Mg-based alloys, Zn-based alloys, Fe-based alloys, and Cu-based alloys. Die casting alloys such as alloys and titanium alloys can be suitably used. Such an alloy for die casting is an alloy used in a normal casting method, and is less expensive than ceramics, amorphous alloys, and the like used in conventional optical connector parts. By press-fitting and molding the alloy into a mold, an injection-molded product such as a component for an optical connector can be easily manufactured.

For example, as the Al-based alloy, ADC1, ADC5, ADC12, etc. according to JIS symbols, such as Al-S
i-based, Al-Mg-based, Al-Si-Cu-based or Al-S
An i-Mg based aluminum alloy for die casting can be suitably used, and ADC12 is particularly useful. Similarly, as the Mg-based alloy, for example, MDC1A, MDC2
A, MDC3A, etc., Mg-Al system or Mg-Al-Z
An n-based magnesium alloy for die casting can be suitably used, and MDC1A is particularly useful. As a Zn-based alloy, for example, AG40A, AG41A, a high Mn alloy, etc., such as Zn-Al-based, Zn-Al-Cu-based, Zn-Al-
A Cu-Mg-based or Zn-Mn-Cu-based zinc alloy for die casting can be suitably used, and a high Mn alloy is particularly useful. Examples of the Fe-based alloy include gray cast iron, austenitic cast iron, stainless cast steel, and the like, and stainless cast steel is particularly useful. In a Cu-based alloy, for example, brass,
There are bronze and aluminum bronze, and aluminum bronze is particularly useful. In addition, examples of the titanium alloy include an α-type alloy, a β-type alloy and an α + β-type alloy, and the α + β-type alloy is particularly useful.

Among these metals, the general formula: Fe _a M _b
X _c (where M is Ni or / and Co, and X is M
n, at least one element selected from Si, Ti, Al, and C;
b ≦ 40, 0 ≦ c ≦ 10, a is the balance containing unavoidable impurities. ) Is preferable as a material for optical connector parts. The Fe-MX-based alloy represented by the above general formula is easily processed with high dimensional accuracy, and has a linear expansion coefficient close to that of an optical fiber. Are suitable.

Although the preferred embodiment of the present invention has been described above, the present invention is not limited to the above-described embodiment, and various design changes are possible. For example, in the above-described method, two products are manufactured in a single injection process using a mold having two product molding cavities.
Although the example of the individual cutting has been described, it is of course possible to use a mold in which three or more cavities are formed in parallel, and to obtain a large number of individual parts, or a single part. In addition, the present invention is not limited to the application example of the ferrule for a single-core optical connector for aligning and connecting optical fibers by abutting the end faces of the ferrules described above. In addition to being applicable to an optical connector member for alignment, it can be applied to the manufacture of various injection molded products having pores.

[0044]

As described above, according to the method and apparatus of the present invention, various problems caused by the use of the core pin used for casting an injection molded article having pores are reduced, and Injection molded products having pores can be continuously produced with good productivity and low cost. As a result, even if it is an amorphous alloy molded product having elongated holes, it can be formed in a simple process and with a predetermined shape, high dimensional accuracy and surface quality, and has excellent durability, strength, impact resistance, etc. An inexpensive amorphous alloy molded product having pores, particularly an optical connector component (ferrule, capillary, etc.) is provided.

[Brief description of the drawings]

FIG. 1 is a partial perspective view schematically showing an embodiment of an apparatus for continuously producing an injection-molded article according to the present invention.

FIG. 2 is a partial cross-sectional view schematically showing one embodiment of an injection molding section of the continuous production apparatus for injection molded articles of the present invention.

FIG. 3 is a schematic explanatory view showing one embodiment of a mold used in the method of the present invention, wherein (A) is a left side view, (B) is a longitudinal sectional view, and (C) is a right side view.

FIG. 4 is a schematic explanatory view showing another embodiment of a mold used in the method of the present invention, wherein (A) is a left side view, (B) is a longitudinal sectional view, and (C) is a right side view. .

FIG. 5 is a schematic explanatory view showing one embodiment of an eject mechanism of a mold used in the method of the present invention, wherein (A) is a left side view,
(B) is a longitudinal sectional view, and (C) is a right side view.

FIG. 6 is a schematic explanatory view showing another embodiment of a mold ejection mechanism used in the method of the present invention, wherein (A) is a left side view, (B) is a longitudinal sectional view, and (C) is a right side view. FIG.

FIGS. 7A and 7B are schematic explanatory views showing one embodiment of a mold centering mechanism used in the method of the present invention, wherein FIG. 7A is a left side view and FIG.
Is a longitudinal sectional view.

FIG. 8 is a schematic explanatory view showing another embodiment of a mold centering mechanism used in the method of the present invention, wherein (A) is a left side view,
(B) is a longitudinal sectional view.

FIG. 9 is a schematic partial cross-sectional view showing one embodiment of a centering mechanism on a tip end side of a cavity of a mold used in the method of the present invention.

FIG. 10 is a schematic partial cross-sectional view showing one embodiment of a centering mechanism on a side of a die in a wire moving direction used in the method of the present invention.

FIG. 11 is a schematic partial sectional view showing a ferrule for an optical connector in which a capillary portion and a flange portion are integrated.

FIG. 12 is a schematic partial cross-sectional view showing a ferrule for an optical connector in which a capillary and a flange are separate bodies.

[Explanation of symbols]

 Reference Signs List 1 mold 2 cavity 3 gate 4 wire (wire material) 5 wire supply reel 6 tension reel 7 injection sleeve 8 injection plunger 13, 14 wire insertion hole 15a, 15b ejector pin 16 electromagnet 17 alignment device A alloy raw material B injection molded product

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C22C 45/04 C22C 45/04 Z 45/08 45/08 45/10 45/10 // B29L 23:00 B29L 23:00 31:36 31:36

Claims (15)

[Claims] 1. A long wire (4) is stretched while being inserted into each cavity of a mold (1) having at least one cavity (2) for regulating the product outer shape, and flows into the cavity. The step of injecting and filling the conductive material and the step of intermittently moving the wire are sequentially repeated to obtain the wire (4).
Manufacturing a series of intermediate products to which a large number of injection molded products (B) are fixed; and pulling a wire (4) from the injection molded product (B) by deforming the wire of the intermediate product by pulling in the axial direction. A method for producing an injection-molded article having pores, comprising the steps of: 2. The wire rod is made of a material having a high elasticity limit,
2. The method according to claim 1, wherein, when the wire is pulled from the injection molded product, the wire is elastically deformed in the drawing direction, whereby the diameter of the wire is reduced, and the wire is pulled out of the injection molded product. 3. The method according to claim 2, wherein the wire is made of a Ni—Ti superelastic alloy. 4. The wire is a wire coated or surface-treated, and when the wire is pulled out from an injection-molded product, a part or all of the film formed by the surface coating or surface treatment is removed from the wire surface. By peeling,
The method of claim 1, wherein the wire is drawn from the injection molded article. 5. A film formed by surface coating or surface treatment of the wire material is an oxide film, a nitride film or a carbon film containing an element constituting the wire material.
The method described in. 6. The method according to claim 4, wherein the wire is made of a Ti-based alloy. 7. The method according to claim 4, wherein the thickness of the film formed by the surface coating or the surface treatment of the wire is 0.5 to 100 μm. 8. The wire having a thickness of from 0.025 mm to φ
The method according to claim 1, wherein the distance is 1 mm. 9. The fluid material according to claim 1, wherein the fluid material is a ceramic paste, a synthetic resin, a metal, or an amorphous alloy containing at least an amorphous phase having a volume ratio of 50% or more. The method according to claim 1. 10. The amorphous alloy according to the following general formula (1)
The method according to claim 9, wherein the alloy is a substantially amorphous alloy having a composition represented by any one of (6) to (6). Formula _{^{(1): M 1 a M}} 2 b Ln c M 3 d M 4 e M 5 f However, one or two elements M ¹ is selected from Zr and Hf, M ² is Ni, Cu, Fe , Co, Mn, Nb, T
at least one element selected from the group consisting of i, V, Cr, Zn, Al and Ga; Ln is Y, La, Ce, N
at least one element selected from the group consisting of d, Sm, Gd, Tb, Dy, Ho, Yb, and Mm (mish metal which is an aggregate of rare earth elements); M ³ is Be, B,
At least one element selected from the group consisting of C, N and O; M ⁴ is at least one element selected from the group consisting of Ta, W and Mo; M ⁵ is Au, Pt, Pd and A;
at least one element selected from the group consisting of g, a,
b, c, d, e and f are each atomic%, and 25 ≦ a ≦
85, 15 ≦ b ≦ 75, 0 ≦ c ≦ 30, 0 ≦ d ≦ 30,
0 ≦ e ≦ 15 and 0 ≦ f ≦ 15. Formula _{(2): Al 100-ghi} Ln g M 6 h M 3 i However, Ln is Y, La, Ce, Nd, Sm, Gd, T
at least one element selected from the group consisting of b, Dy, Ho, Yb, and Mm; M ⁶ is Ti, V, Cr, Mn,
Fe, Co, Ni, Cu, Zr, Nb, Mo, Hf, T
at least one element selected from the group consisting of a and W, M ³ is at least one element selected from the group consisting of Be, B, C, N, and O; g, h, and i are each atomic%; 30 ≦ g ≦ 90, 0 <h ≦ 55, 0 ≦ i ≦ 10
It is. General formula (3): Mg _100-p M ⁷ _p where M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, and p is atomic percentage 5 ≦ p ≦
60. General formula (4): Mg _100-qr M ⁷ _q M ⁸ _r where M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, and M ⁸ is made of Al, Si and Ca At least one element selected from the group: q
And r are each atomic%, 1 ≦ q ≦ 35, 1 ≦ r ≦ 2
5 General formula (5): Mg _100-qs M ⁷ _q M ⁹ _s where M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, and M ⁹ is Y, La, C
at least one element selected from the group consisting of e, Nd, Sm and Mm, q and s are each atomic%, and 1 ≦ q
≦ 35 and 3 ≦ s ≦ 25. General formula (6): Mg _100-qrs M ⁷ _q M ⁸ _r M ⁹ _s where M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, M ⁸ is Al, Si and At least one element selected from the group consisting of Ca, M
⁹ is at least one element selected from the group consisting of Y, La, Ce, Nd, Sm and Mm, q, r and s are each atomic%, and 1 ≦ q ≦ 35, 1 ≦ r ≦ 25, 3 ≦ s ≦
25. 11. The method according to claim 1, wherein the injection molded article is an optical connector part for inserting or holding an optical fiber. 12. A mold (1) having at least one cavity (2) for regulating a product outer shape; and a long wire (4) stretched in a state inserted into each cavity of the mold. A means (6) for stretching and intermittently moving the wire; an injection means (7, 8) for injecting a fluid material into the cavity of the mold; and an injection means (7, 8); And a means for applying a tensile load in the axial direction to an intermediate wire obtained in a state where the injection-molded product (B) is fixed to the injection-molded product (B), and pulling the wire from the injection-molded product. Equipment for manufacturing molded products. 13. The apparatus according to claim 12, further comprising a centering mechanism in one or both of the front and rear of the mold in the wire moving direction. 14. The mold (1) has at least one cavity (2a) opened on the wire moving direction side,
A mold part (1a) including ejector means (15a, 15b) capable of protruding in the wire moving direction into the cavity.
14. The apparatus according to claim 12, further comprising: a split mold portion (1 b, 1 c) arranged on the wire moving direction side of the mold portion and having the wire insertion portion as a parting surface. . 15. The device according to claim 14, wherein the split portions (1b, 1c) have cavities (2b) opening on the opposite side to the direction of wire movement.