JP2005342923A

JP2005342923A - Composite part molding method

Info

Publication number: JP2005342923A
Application number: JP2004162473A
Authority: JP
Inventors: Takahiro Harada; 高宏原田; Hiroaki Kurasumi; 博章倉住; Tetsuya Yamamoto; 哲也山本
Original assignee: Matsushita Electric Works Ltd
Current assignee: Panasonic Electric Works Co Ltd
Priority date: 2004-05-31
Filing date: 2004-05-31
Publication date: 2005-12-15
Anticipated expiration: 2024-05-31
Also published as: JP4419686B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding method of a composite part 5 capable of extending the life of a punch 40 and cutting/molding an insert part 1 in the same mold. <P>SOLUTION: After an insert part 1 is arranged in a mold 10 and the mold 10 is closed to fix the insert part 1 in the mold 10, the base 45 of a punch 40 independently movable with respect to the mold 10 is pressed to the insert part 1 in the vicinity of the cutting region 35 thereof to cut the insert part 1, the punch 40 is further pressed down while deforming the frame region 30 of the insert part 1 to form a cavity 55 by the mold 10 and the side surface 50 of the punch 40 and a resin is subsequently injected in the cavity 55 and cured before performing mold opening. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、金属回路線・金属端子等の金属部品を樹脂内に固定するように成形された成形方法に関し、特にコネクタ・リレー等の電気部品の製造方法に有効な技術である。 The present invention relates to a molding method in which metal parts such as metal circuit lines and metal terminals are fixed in a resin, and is particularly effective in a method for manufacturing electrical parts such as connectors and relays.

従来から、特開昭６０−２５３５２０号公報や特開平７−１０８５４３号公報に示される如く、金属部を備えた複合部品は主に電気部品に用いられ、その成形方法としては同一型内で金属片を切断し、樹脂を注入・硬化させる方法が知られている。この種の成形方法では、一般に、特開昭６０−２５３５２０号公報で説明されているように、パンチが型内のキャビティと離れた場所に配されており、樹脂を注入・硬化させる部分と金属片を切断する部分が離れた構造となっていた。また、特開平７−１０８５４３号公報では筒状ガイドを備えてパンチの底面をパンチに押し当てた状態で樹脂を注入・硬化させることにより、部品の効率的な製造を可能とするものであった。 Conventionally, as disclosed in JP-A-60-253520 and JP-A-7-108543, composite parts having metal parts have been mainly used for electric parts. A method of cutting a piece and injecting and curing a resin is known. In this type of molding method, generally, as described in JP-A-60-253520, the punch is disposed at a location away from the cavity in the mold, and a portion for injecting and curing resin and a metal The part which cut | disconnects a piece was a separated structure. Japanese Patent Application Laid-Open No. 7-108543 discloses that a cylindrical guide is provided, and a resin is injected and cured in a state where the bottom surface of the punch is pressed against the punch, thereby enabling efficient production of parts. .

しかしながら、特開昭６０−２５３５２０号公報の場合には、樹脂を注入・硬化させる部分と金属片の切断部分とがほとんど離間していない複合部品を成形する場合には、金属片を固定するための部位を型内に型内に設けることが困難であり、仮に設けることができたとしてもその部位近傍の型の肉厚が薄くなるため、射出成形等の高圧力が負荷される成形時には型が塑性変形するという問題があった。 However, in the case of Japanese Patent Application Laid-Open No. 60-253520, in the case of molding a composite part in which the resin injection / curing part and the cut part of the metal piece are hardly separated, the metal piece is fixed. It is difficult to provide the part in the mold in the mold, and even if it can be provided, the thickness of the mold near the part becomes thin. However, there was a problem of plastic deformation.

又、特開平７−１０８５４３号公報の場合には、パンチの底面をインサート部品に押し当てた状態で樹脂を注入・硬化しているため、パンチ底面に樹脂が付着して、パンチの寿命を短くするという問題があった。更には、筒状ガイドで切断部位の近傍を固定した状態で成形しているため、成形後にインサート部品の筒状ガイドで固定していた部位が封止できずに露出してしまい、インサート部品の密着強度および信頼性の面で問題もあった。
特開昭６０−２５３５２０号公報特開平７−１０８５４３号公報 In the case of Japanese Patent Application Laid-Open No. 7-108543, since the resin is injected and cured with the bottom surface of the punch pressed against the insert part, the resin adheres to the bottom surface of the punch and shortens the life of the punch. There was a problem to do. Furthermore, since the vicinity of the cutting part is fixed with the cylindrical guide, the part fixed with the cylindrical guide of the insert part is exposed after sealing without being sealed. There were also problems in terms of adhesion strength and reliability.
JP-A-60-253520 Japanese Patent Laid-Open No. 7-108543

本願発明は、上記背景技術に鑑みて発明されたものであり、その課題は、型の厚みを必要以上に薄肉化する必要がなく、またパンチを長寿命化できる複合部品の成形方法を提供することである。 The present invention has been invented in view of the above-described background art, and its object is to provide a method for forming a composite part that does not require the thickness of the mold to be unnecessarily thin and can extend the life of the punch. That is.

上記課題を解決するために、本願発明は、複合部品内に残留する機能部位と、型内への位置決め又は搬送に用いるためのフレーム部位、機能部位とフレーム部位の境界部に切断部位を備えたインサート部品を型内に配置する配置工程と、型を閉じることにより型内にインサート部品の機能部位を固定する固定工程と、固定されたインサート部品の切断部位近傍のフレーム部位に、型に対して独立移動可能なパンチ底面を押し当てることによりインサート部品を切断部位で切断する切断工程と、インサート部品のフレーム部位を変形させつつパンチを更に押し下げて、型とパンチ側面でキャビティを形成するキャビティ形成工程と、キャビティに樹脂を注入・硬化させることにより、インサート部品の機能部位を有する複合部品を成形する成形工程と、パンチをキャビティ内より抜き取り、型を開いて複合部品を取り出す型開き工程と、を含んで複合部品を成形することである。 In order to solve the above-described problems, the present invention includes a functional part remaining in the composite part, a frame part for use in positioning or conveyance in the mold, and a cutting part at the boundary between the functional part and the frame part. Placement process for placing the insert part in the mold, fixing process for fixing the functional part of the insert part in the mold by closing the mold, and the frame part near the cutting part of the fixed insert part with respect to the mold A cutting process for cutting the insert part at the cutting site by pressing the independently movable punch bottom, and a cavity forming process for forming a cavity on the die and the side of the punch by further pressing down the punch while deforming the frame part of the insert part Molding to form composite parts with functional parts of insert parts by injecting and curing resin into the cavity Degree and the punch withdrawn from the cavity, a step to open the mold is taken out composite parts open the mold and to mold the composite part contains.

本願発明の複合部品の成形方法においては、複合部品内に残留する機能部位と、型内への位置決め又は搬送に用いるためのフレーム部位、機能部位とフレーム部位の境界部に切断部位を備えたインサート部品を型内に配置し、型を閉じることにより型内にインサート部品を固定した後、インサート部品の切断部位近傍に、型に対して独立移動可能なパンチ底面を押し当てることによりインサート部品を切断し、インサート部品のフレーム部位を変形させつつパンチを更に押し下げて、型とパンチ側面でキャビティを形成した後、キャビティに樹脂を注入・硬化させて、複合部品を取り出す型開きを行うので、パンチとキャビティ間の型の部分を薄肉にする必要がない。また、パンチ底面が樹脂注入時にキャビティの外側に配されているので、パンチ底面に樹脂が付着することを防止でき、パンチを長寿命化することができる。 In the method for molding a composite part of the present invention, a functional part remaining in the composite part, a frame part for use in positioning or conveying into the mold, and an insert having a cutting part at the boundary between the functional part and the frame part After placing the part in the mold and closing the mold to fix the insert part in the mold, the insert part is cut by pressing the bottom of the punch that can move independently of the mold near the cutting part of the insert part. Then, the punch is further pushed down while deforming the frame part of the insert part, and after forming the cavity with the mold and the side of the punch, the mold is opened by injecting and curing resin into the cavity and taking out the composite part. There is no need to make the mold part between the cavities thinner. In addition, since the bottom surface of the punch is disposed outside the cavity when the resin is injected, it is possible to prevent the resin from adhering to the bottom surface of the punch and to extend the life of the punch.

図１〜５は、本願の請求項１・２の両方に対応した一実施形態である複合部品５の成形方法を示している。まず、成形装置を説明する。この実施形態で用いる成形装置は、インサート部品１を内部に固定し、そこに樹脂を注入して賦形するための型１０と、型１０内を上下方向に型１０から独立して移動可能に設けられ、型１０内に配置されたインサート部品１の一部位を切断するためのパンチ４０で構成されている。 1-5 has shown the shaping | molding method of the composite component 5 which is one Embodiment corresponding to both Claim 1 * 2 of this application. First, the molding apparatus will be described. The molding apparatus used in this embodiment is a mold 10 for fixing the insert part 1 inside, and injecting resin into the mold 10, and the inside of the mold 10 can be moved independently from the mold 10 in the vertical direction. It is provided with a punch 40 for cutting one part of the insert part 1 disposed in the mold 10.

この実施形態に用いられているインサート部品１は、厚み０．１２ｍｍの銅板を打抜き加工を行って穴加工した後、プレス加工により一部を突起形状部位としたものであり、２個の突起形状部位とそれらを繋ぐ平坦部位とにより構成される複数の機能部位２５と、外周部を含む機能部位２５以外の部位であるフレーム部位３０と、機能部位２５とフレーム部位３０との境界に位置する複数の切断部位３５と、を備えている。（図２） The insert part 1 used in this embodiment is formed by punching a copper plate having a thickness of 0.12 mm to make a hole, and then making a part into a protrusion-shaped portion by pressing. A plurality of functional parts 25 constituted by parts and flat parts connecting them, a frame part 30 which is a part other than the functional part 25 including the outer periphery, and a plurality located at the boundary between the functional part 25 and the frame part 30 And a cutting portion 35. (Figure 2)

また、この実施形態に用いられる型１０は、固定型である下型１１と、可動型である上型１２で構成されており、上下方向に上型１２が移動することにより、型開きや型閉じが可能な構造となっている。 In addition, the mold 10 used in this embodiment includes a lower mold 11 that is a fixed mold and an upper mold 12 that is a movable mold. It has a structure that can be closed.

下型１１は、樹脂を注入する際にゲートの一部を構成するゲート溝１９と、ゲート溝１９に連なり樹脂注入時にはその上面がキャビティ５５の下壁となるキャビティ下部構成用部位１５と、複合部品５内に残留させるインサート部品１の機能部位２５をキャビティ下部構成用部位１５よりも上方に配するために、キャビティ下部構成用部位１５の両側に設けられた複数の凸部形状よりなる機能部位配置用部位１３と、インサート部品１の一部位を切断するためのパンチ４０の移動領域を確保するために、パンチ底面４５形状と略同一の断面形状を有し、キャビティ下部構成用部位１５よりもその底面が下に位置するパンチ逃がし溝１７と、を備えている。（図１） The lower mold 11 is composed of a gate groove 19 that constitutes a part of the gate when resin is injected, a cavity lower portion 15 that is connected to the gate groove 19 and whose upper surface becomes the lower wall of the cavity 55 when resin is injected, In order to arrange the functional part 25 of the insert part 1 to be left in the part 5 above the cavity lower part constituting part 15, the functional part composed of a plurality of convex portions provided on both sides of the cavity lower part constituting part 15 In order to secure the movement region of the punch 40 for cutting the part 13 for placement and one part of the insert part 1, it has substantially the same cross-sectional shape as the shape of the bottom face 45 of the punch, and is lower than the part 15 for configuring the cavity lower part. And a punch relief groove 17 whose bottom surface is located below. (Figure 1)

上型１２は、下型１１のキャビティ構成用部位の真上に位置し、樹脂注入時にはキャビティ５５の上壁となるキャビティ上部構成用部位１６と、インサート部品１の機能部位２５を下型１１の機能部位配置用部位１３との間で挟み込んで固定するために、キャビティ上部構成用部位１６の両側に設けられ、その底面がインサート部品１の機能部位２５の突起形状部位に倣った凹面形状を備えた機能部位固定用部位１４と、パンチ４０の上下方向のスライド移動を可能にするために設けられ、パンチ底面４５形状と略同一の断面形状を有する貫通穴であるパンチスライド穴１８と、下型１１のゲート溝１９の真上に位置し、樹脂注入時にゲートの一部となる上下方向貫通穴である樹脂注入口２０（図４）と、を備えている。（図３） The upper mold 12 is located immediately above the cavity constituting part of the lower mold 11, and the upper part constituting part 16 serving as the upper wall of the cavity 55 and the functional part 25 of the insert part 1 are inserted into the lower mold 11 when resin is injected. In order to be sandwiched between and fixed to the functional part arranging part 13, it is provided on both sides of the cavity upper part 16 and the bottom surface has a concave shape following the protruding part of the functional part 25 of the insert part 1. A functional part fixing part 14, a punch slide hole 18 which is provided to enable the slide movement of the punch 40 in the vertical direction and has a sectional shape substantially the same as the shape of the bottom face 45 of the punch, and a lower mold 11 is provided with a resin injection port 20 (FIG. 4) that is a vertical through hole that is positioned directly above the 11 gate grooves 19 and becomes a part of the gate during resin injection. (Figure 3)

パンチ４０は、上型１２とは独立で上下方向に移動制御可能にするための、上型１２の駆動機構とは別の駆動機構（図示せず）と、下型１１のキャビティ下部構成用部位１５の側面及び機能部位配置用部位１３の側面で構成される凹凸形状に倣った断面を上下方向に延伸させた角柱形状を備えた先端部と、インサート部品１を切断する際の磨耗を低減するために硬質加工が施され、かつキャビティ下部構成用部位１５とパンチ逃がし溝１７の外側部位間を繋ぐ平面よりも傾斜した傾斜面となっているパンチ底面４５と、を備えている。また、パンチ４０は、下型１１のキャビティ下部構成用部位１５の側面及び機能部位配置用部位１３の側面と０．００３ｍｍ〜０．０１０ｍｍのクリアランスを有しながら、上型１２のパンチスライド穴１８および下型１１のパンチ逃がし溝１７内を上下方向に移動可能な構造となっている。（図５（A）） The punch 40 is independent of the upper die 12 and can be moved and controlled in the vertical direction. The punch 40 has a driving mechanism (not shown) different from the driving mechanism of the upper die 12 and a cavity lower component part of the lower die 11. Reduces wear when cutting the insert part 1 and a tip portion having a prismatic shape in which a cross section following the concave and convex shape formed by the side surfaces of the 15 side surfaces and the functional site arranging portion 13 is vertically extended. Therefore, a punch bottom surface 45 is provided which is hard-worked and has an inclined surface inclined with respect to a plane connecting the cavity lower portion constituting portion 15 and the outer portion of the punch escape groove 17. Further, the punch 40 has a clearance of 0.003 mm to 0.010 mm from the side surface of the cavity lower portion constituting portion 15 and the side surface of the functional portion arranging portion 13 of the lower die 11, and the punch slide hole 18 of the upper die 12. And, it has a structure that can move in the punch escape groove 17 of the lower mold 11 in the vertical direction. (Fig. 5 (A))

次に複合部品５の成形方法について説明する。この実施形態においては、複合部品５内に残留する機能部位２５と、型１０内への位置決め又は搬送に用いるためのフレーム部位３０と、機能部位２５とフレーム部位３０の境界部に切断部位３５を備えたインサート部品１を型１０内に配置する配置工程と、型１０を閉じることにより型１０内にインサート部品１の機能部位２５を固定する固定工程と、固定されたインサート部品１の切断部位３５近傍のフレーム部位３０に、型１０に対して独立移動可能なパンチ底面４５を押し当てることによりインサート部品１を切断部位３５で切断する切断工程と、インサート部品１のフレーム部位３０を変形させつつパンチ４０を更に押し下げて、型１０とパンチ側面５０でキャビティ５５を形成するキャビティ形成工程と、キャビティ５５に樹脂を注入・硬化させることにより、インサート部品１の機能部位２５を有する複合部品５を成形する成形工程と、パンチ４０をキャビティ５５内より抜き取り、型１０を開いて複合部品５を取り出す型開き工程とを行うことにより、複合部品５を成形している。これにより、型１０の厚みを必要以上に薄肉化する必要がなく、またパンチ底面４５に樹脂が付着することもないので、パンチ４０の長寿命化を可能にしている。 Next, a method for forming the composite part 5 will be described. In this embodiment, a functional part 25 remaining in the composite part 5, a frame part 30 for use in positioning or conveying into the mold 10, and a cutting part 35 at the boundary between the functional part 25 and the frame part 30. An arrangement step of arranging the provided insert part 1 in the mold 10, a fixing step of fixing the functional part 25 of the insert part 1 in the mold 10 by closing the mold 10, and a cutting part 35 of the fixed insert part 1 A cutting process in which the insert part 1 is cut at the cutting part 35 by pressing a punch bottom surface 45 that can move independently of the mold 10 against the frame part 30 in the vicinity, and a punch while deforming the frame part 30 of the insert part 1 40 is further pushed down to form a cavity 55 between the mold 10 and the punch side surface 50, and a resin is applied to the cavity 55. A molding process for molding the composite part 5 having the functional part 25 of the insert part 1 by injection and curing, and a mold opening process for extracting the punch 40 from the cavity 55 and opening the mold 10 to take out the composite part 5. By doing so, the composite part 5 is molded. Thereby, it is not necessary to reduce the thickness of the mold 10 more than necessary, and the resin does not adhere to the punch bottom surface 45, so that the life of the punch 40 can be extended.

更には、キャビティ形成工程時に、パンチ４０を押し下げることにより、インサート部品１のフレーム部位３０の一部を塑性変形させており、これにより型開き後にインサート部品１のフレーム部位３０が切断工程前の形状に戻ろうとしてスプリングバックが生じ、複合部品５に傷をつけることを防止している。これらの各工程における詳細について下記に説明する。 Furthermore, a part of the frame part 30 of the insert part 1 is plastically deformed by pushing down the punch 40 during the cavity forming process, so that the frame part 30 of the insert part 1 is shaped before the cutting process after the mold is opened. As a result, a spring back is generated to return to the point, and the composite part 5 is prevented from being damaged. Details of each of these steps will be described below.

図２に配置工程の段階を示す要部の斜視図を示す。図２に示すように、この実施形態での配置工程は、インサート部品１の切断部位３５と連なるフレーム部位３０が下型１１の機能部位配置用部位１３と下型１１のパンチ逃がし溝１７の外側部位との間を載架し、かつインサート部品１の機能部位２５の突起形状部位が上を向くように、インサート部品１を下型１１内に配置する。このとき、インサート部品１の切断部位３５は下型１１の機能部位配置用部位１３の上面外周上に、かつインサート部品１の機能部位２５は下型１１の機能部位配置用部位１３の上となるように正確に配置する必要があり、そのために図示はしていないが、インサート部品１のフレーム部位３０の一部に位置決め穴を、下型１１に位置決めピンを設けて、下型１１の位置決めピンにインサート部品１の位置決め穴を挿通することにより、インサート部品１の下型１１に対する位置決め精度を０．０１ｍｍ以内に保持している。 FIG. 2 is a perspective view of a main part showing the stage of the arrangement process. As shown in FIG. 2, in the arrangement step in this embodiment, the frame part 30 connected to the cutting part 35 of the insert part 1 is located outside the functional part arranging part 13 of the lower mold 11 and the punch relief groove 17 of the lower mold 11. The insert part 1 is placed in the lower mold 11 so as to be placed between the parts and so that the protrusion-shaped part of the functional part 25 of the insert part 1 faces upward. At this time, the cutting part 35 of the insert part 1 is on the outer periphery of the upper surface of the functional part arranging part 13 of the lower mold 11, and the functional part 25 of the insert part 1 is above the functional part arranging part 13 of the lower mold 11. However, although not shown in the drawing, a positioning hole is provided in a part of the frame part 30 of the insert part 1 and a positioning pin is provided in the lower mold 11 so that the positioning pin of the lower mold 11 is provided. The positioning accuracy of the insert part 1 with respect to the lower mold 11 is maintained within 0.01 mm by inserting the positioning hole of the insert part 1 into the insert part 1.

図３に固定工程の段階を示す要部の斜視図を示す。図３に示すように、この実施形態での固定工程は、下型１１内に配置されたインサート部品１を、上型１２を下方向に移動させて、インサート部品１の機能部位２５の突起形状部位を上型１２の機能部位固定用部位１４と下型１１の機能部位配置用部位１３間で、フレーム部位３０の外周部周辺を上型１２のパンチスライド穴１８の外側部位と下型１１のパンチ逃がし溝１７の外側部位間で、上型１２に２０００〜５０００Nの荷重を負荷して挟み込んで、インサート部品１を型１０内に固定している。このとき、上型１２の機能部位固定用部位１４の間に位置するキャビティ上部構成用部位１６の底面と下型１１の機能部位配置用部位１３の間に位置するキャビティ下部構成用部位１５の上面とは、樹脂を注入できる隙間を備えて対向している。 FIG. 3 is a perspective view of the main part showing the stage of the fixing process. As shown in FIG. 3, the fixing process in this embodiment is performed by moving the upper part 12 downward in the insert part 1 arranged in the lower mold 11, and the protrusion shape of the functional part 25 of the insert part 1. The part is between the functional part fixing part 14 of the upper mold 12 and the functional part arranging part 13 of the lower mold 11, and the outer peripheral part of the frame part 30 is outside the punch slide hole 18 of the upper mold 12 and the lower mold 11. The insert part 1 is fixed in the mold 10 by applying a load of 2000 to 5000 N to the upper mold 12 between the outer portions of the punch relief grooves 17. At this time, the upper surface of the cavity lower component part 15 located between the bottom surface of the cavity upper component part 16 located between the functional part fixing parts 14 of the upper mold 12 and the functional part arrangement part 13 of the lower mold 11. Are opposed to each other with a gap through which resin can be injected.

図４に切断工程の段階を示す全体の斜視図を示す。図４に示すように、この実施形態での切断工程は、型閉じされた上型１２のパンチスライド穴１８内に先端部が配置されたパンチ４０を、上型１２の駆動機構とは別の駆動機構（図示せず）を用いて、下方向に移動させてインサート部品１のフレーム部位３０にパンチ底面４５を押し当てている。そして、更にパンチ４０を下方向に移動させて、パンチ底面４５と下型１１の機能部位配置用部位１３との間の部位、つまりインサート部品１の機能部位２５とフレーム部位３０の境界部位である切断部位３５でインサート部品１を、パンチ４０に５００００N以上の荷重を負荷して切断し、インサート部品１の機能部位２５とフレーム部位３０を切り離している。 FIG. 4 is an overall perspective view showing the steps of the cutting process. As shown in FIG. 4, the cutting process in this embodiment is performed in such a manner that the punch 40 whose tip is disposed in the punch slide hole 18 of the upper mold 12 which is closed is separated from the drive mechanism of the upper mold 12. Using a drive mechanism (not shown), the punch bottom surface 45 is pressed against the frame part 30 of the insert part 1 by moving downward. Further, the punch 40 is further moved downward to be a part between the punch bottom face 45 and the functional part arranging part 13 of the lower mold 11, that is, a boundary part between the functional part 25 of the insert part 1 and the frame part 30. The insert part 1 is cut at the cutting part 35 by applying a load of 50000 N or more to the punch 40, and the functional part 25 and the frame part 30 of the insert part 1 are separated.

図５（A）（B）にキャビティ形成工程の段階を示す要部の斜視図および断面図を示す。図5（A）に示すように、この実施形態でのキャビティ形成工程は、インサート部品１の切断部位３５を切断した後もパンチ４０を下方向に移動させて、下型１１の機能部位配置用部位１３と下型１１のパンチ逃がし溝１７の外側部位との間を橋梁していたフレーム部位３０を下方向に押し下げることにより行われる。そして、上型１２のパンチスライド穴１８の外側部位と下型１１のパンチ逃がし溝１７の外側部位間で挟み込まれたフレーム部位３０と、下型１１の機能部位配置用部位１３と下型１１のパンチ逃がし溝１７の外側部位との間を橋梁していたフレーム部位３０との境界部付近で、インサート部品１が塑性変形させられている。これにより、型開き後にインサート部品１のフレーム部位３０が切断工程前の形状に戻ろうとスプリングバックして、複合部品５に傷をつけることを防止できるものである。また、図５（B）に示すように、パンチ底面４５が下型１１のキャビティ下部構成用部位１５の上面よりも下になるまで、パンチ４０を下方向に移動させるので、それにより上型１２のキャビティ上部構成用部位１６の底面と、下型１１のキャビティ下部構成用部位１５の上面と、パンチ側面５０とで、インサート部品１の機能部位２５を中に含んだキャビティ５５が同時に形成される。 5A and 5B are a perspective view and a cross-sectional view of the main part showing the stage of the cavity forming process. As shown in FIG. 5 (A), in the cavity forming step in this embodiment, the punch 40 is moved downward even after the cutting part 35 of the insert part 1 is cut, so that the functional part of the lower mold 11 is arranged. This is performed by pushing down the frame part 30 that has bridged between the part 13 and the outer part of the punch relief groove 17 of the lower mold 11. The frame part 30 sandwiched between the outer part of the punch slide hole 18 of the upper mold 12 and the outer part of the punch relief groove 17 of the lower mold 11, the functional part arranging part 13 of the lower mold 11, and the lower mold 11 The insert part 1 is plastically deformed in the vicinity of the boundary with the frame part 30 that has bridged between the outer part of the punch relief groove 17. Thereby, it is possible to prevent the frame part 30 of the insert part 1 from returning to the shape before the cutting process after the mold is opened and damaging the composite part 5. Further, as shown in FIG. 5 (B), the punch 40 is moved downward until the bottom surface 45 of the punch is lower than the upper surface of the cavity lower portion constituting portion 15 of the lower die 11. The cavity 55 including the functional part 25 of the insert part 1 is simultaneously formed by the bottom surface of the cavity upper part 16, the upper surface of the cavity lower part 15 of the lower mold 11, and the punch side surface 50. .

この実施形態での成形工程では、上型１２の樹脂注入口２０（図４）より熱硬化性樹脂液を流し込み、流し込まれた熱硬化性樹脂液が下型１１のゲート溝１９を介して、上型１２のキャビティ上部構成用部位１６の底面と下型１１のキャビティ下部構成用部位１５の上面とパンチ側面５０とで形成されるキャビティ５５内へと注入される。その後、型から伝わる熱により、熱硬化性樹脂液を硬化させることにより、インサート部品１の機能部位２５と樹脂部６０とを備えた複合部品５（図６）を成形する。 In the molding process in this embodiment, a thermosetting resin liquid is poured from the resin inlet 20 (FIG. 4) of the upper mold 12, and the poured thermosetting resin liquid is passed through the gate groove 19 of the lower mold 11. It is injected into a cavity 55 formed by the bottom surface of the cavity upper part 16 of the upper die 12, the upper surface of the cavity lower part 15 of the lower die 11, and the punch side surface 50. Then, the composite part 5 (FIG. 6) provided with the functional part 25 of the insert part 1 and the resin part 60 is shape | molded by hardening | curing a thermosetting resin liquid with the heat | fever transmitted from a type | mold.

この実施形態での型開き工程では、パンチ底面４５が上型１２のキャビティ上部構成用部位１６の底面よりも上になるまで、パンチ４０を上方向に移動させて、キャビティ５５内からパンチ４０を引き抜いた後、上型１２を上方向に移動させて、型開きを行う。その後、キャビティ下部構成用部位１５内に備えたイジェクタピン（図示せず）を上方向に移動させて複合部品５を取り出す。上記のように型開き時に上型１２とパンチ４０とを別々のタイミングで上方向に移動させることにより、型開き時に複合部品５に負荷される離型時の抵抗を分散することができるので、離型抵抗による複合部品５の欠けを防止できる。 In the mold opening process in this embodiment, the punch 40 is moved upward until the punch bottom surface 45 is above the bottom surface of the cavity upper component part 16 of the upper mold 12, and the punch 40 is removed from the cavity 55. After pulling out, the upper mold 12 is moved upward to perform mold opening. Thereafter, an ejector pin (not shown) provided in the cavity lower portion 15 is moved upward to take out the composite part 5. Since the upper mold 12 and the punch 40 are moved upward at different timings at the time of mold opening as described above, the resistance at the time of mold release applied to the composite part 5 at the time of mold opening can be dispersed. Chipping of the composite part 5 due to mold release resistance can be prevented.

このようにインサート部品１を備えた複合部品５の成形が行われるが、パンチ側面５０がキャビティ５５の一面を形成するので、パンチ４０とキャビティ５５の間の型１０部分を薄肉にする必要もなく、また、パンチ底面４５が樹脂注入時にキャビティ５５の外側に配されているので、パンチ底面４５に樹脂が付着することを防止でき、パンチ４０の寿命を長寿命化することができる。
なお、上記実施形態では、複合部品５の樹脂部６０を構成する樹脂を熱硬化性樹脂としたが、熱可塑性樹脂を用いても良い。 Thus, although the composite part 5 provided with the insert part 1 is molded, since the punch side surface 50 forms one surface of the cavity 55, it is not necessary to make the die 10 portion between the punch 40 and the cavity 55 thin. In addition, since the bottom surface 45 of the punch is arranged outside the cavity 55 when the resin is injected, it is possible to prevent the resin from adhering to the bottom surface 45 of the punch, and the life of the punch 40 can be extended.
In the above embodiment, the resin constituting the resin portion 60 of the composite component 5 is a thermosetting resin, but a thermoplastic resin may be used.

本願発明の一実施形態に用いる下型の（A）は全体斜視図、（B）は要部の斜視図。The lower mold | type (A) used for one Embodiment of this invention is a whole perspective view, (B) is a perspective view of the principal part. 本願発明の一実施形態における配置工程の段階を示す要部の斜視図。The perspective view of the principal part which shows the step of the arrangement | positioning process in one Embodiment of this invention. 本願発明の一実施形態における固定工程の段階を示す要部の斜視図。The perspective view of the principal part which shows the step of the fixing process in one Embodiment of this invention. 本願発明の一実施形態における切断工程の段階を示す全体斜視図。The whole perspective view which shows the step of the cutting process in one Embodiment of this invention. 本願発明の一実施形態におけるキャビティ形成工程の段階を示す（A）は要部の斜視図、（B）は要部の断面図。(A) is a perspective view of the principal part, (B) is sectional drawing of the principal part which shows the step of the cavity formation process in one Embodiment of this invention. 本願発明の一実施形態にて作製された複合部品の斜視図。The perspective view of the composite component produced in one Embodiment of this invention.

Explanation of symbols

１インサート部品
５複合部品
１０型
２５機能部位
３０フレーム部位
３５切断部位
４０パンチ
４５パンチ底面
５０パンチ側面
５５キャビティ DESCRIPTION OF SYMBOLS 1 Insert part 5 Composite part 10 Type 25 Functional part 30 Frame part 35 Cutting part 40 Punch 45 Punch bottom face 50 Punch side face 55 Cavity

Claims

A method for forming a composite part, comprising the following steps.
(1) Insert a component with a functional part remaining in the composite part, a frame part for use in positioning or transporting into the mold, and a cutting part at the boundary between the functional part and the frame part into the mold. Arrangement process to arrange.
(2) A fixing step of fixing the functional part of the insert part in the mold by closing the mold.
(3) A cutting step of cutting the insert part at the cutting site by pressing the bottom surface of the punch that can be moved independently of the mold against the frame part near the cutting site of the fixed insert part.
(4) A cavity forming step in which the punch is further pushed down while the frame part of the insert part is deformed to form a cavity between the die and the side surface of the punch.
(5) A molding process for molding a composite part having a functional part of an insert part by injecting and curing resin into the cavity.
(6) A mold opening process in which the punch is removed from the cavity and the mold is opened to take out the composite part.

The method for forming a composite part according to claim 1, wherein the cavity forming step plastically deforms a frame portion of the insert part by pressing down a punch.