JP2007006572A - Molding unit - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce the manufacture cost by absorbing the dispersion of the thickness of stacked core materials and dispensing with management such as selection of core materials. <P>SOLUTION: This is a molding unit which molds an insert core by clamping two or more sheets of core materials stacked in the inner space constituted of a fixed mold 20 and a movable mold 40 and injecting fused resin into one part of the inner space. It is equipped with a floating mold 30 which is built in the fixed mold 20 so that it may reciprocate in the stacking direction of the core materials, a supporting face 32 which is provided in the floating mold capably of supporting the core materials in stacked state, and a pressing means (spring 38) which gives specified pressure to the floating mold from the opposite side of the supporting face. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a molding apparatus for insert molding with a resin material in a state where a plurality of core materials such as a rotor core, a stator core, and a yoke constituting a motor are laminated.

For this type of molding apparatus, for example, the technique disclosed in Patent Document 1 is already known. In this technique, a plurality of core materials processed into a plate shape in advance are set in a fixed mold of a resin molding die. Next, after the movable mold is operated toward the fixed mold and the mold is clamped, molten resin is injected into the space (cavity) in the mold. When the resin material is cured, the core materials are bonded in a laminated state, and an insert core is formed.
JP 2001-95193 A

  In the state in which the core materials, which are metal plates, are laminated, the overall thickness varies due to the spring effect of each core material. Due to this variation, when the thickness is small, a gap is formed between the inner surface of the mold and the core material in the clamped state, causing resin leakage and burrs. If the thickness is large, the mold is not sufficiently closed. For this reason, additional work such as selecting the core material and managing the thickness of the core material in the laminated state is necessary, which leads to an increase in the cost of the product.

  The present invention is intended to solve such a problem, and its purpose is to absorb the variation in the thickness of the laminated core materials and to reduce the product cost by eliminating the management such as selection of the core materials. is there.

The present invention is for achieving the above object, and is configured as follows.
A molding apparatus that molds an insert core by clamping a mold in a state where a plurality of core materials are stacked in an internal space constituted by a fixed mold and a movable mold, and injecting a molten resin into a part of the internal space. A floating type incorporated so as to be able to reciprocate in the stacking direction of the core material with respect to the fixed type, a support surface provided in the floating type so as to be able to support the core material in the stacked state, and a support surface with respect to the floating type Pressing means for applying a predetermined pressing force from the opposite side.

  According to this configuration, in the mold clamping state, the floating mold that supports the laminated core material moves so as to absorb the variation in the thickness of the entire core material using the pressing force by the pressing means as a cushion. As a result, the contact state between the inner surface of the movable mold and the core material is always maintained properly, and operations such as managing the thickness of the core material and selecting it are not required, and the product cost can be reduced. .

  The pressing means is preferably a spring provided between the fixed mold and the floating mold in order to reduce the cost of the molding apparatus. Further, the pressing means may be a cylinder provided between the fixed type and the floating type.

Furthermore, the present invention is configured as follows.
A molding apparatus that molds an insert core by clamping a mold in a state where a plurality of core materials are stacked in an internal space constituted by a fixed mold and a movable mold, and injecting a molten resin into a part of the internal space. The floating mold incorporated so that it can reciprocate in the stacking direction of the core material with respect to the fixed mold, the support surface provided in the floating mold so as to support the core material in the stacked state, and the reciprocating rotation around the axis A pressing shaft that can advance and retreat in the same direction as the floating mold and that is in contact with the floating mold on the opposite side of the support surface, a rotational drive means that can reciprocate the pressing shaft, and a core material in a stacked state And a control means for controlling the rotational drive of the rotational drive means based on a detection signal from the detection means.

  In this configuration, the pressure on the core material can be finely adjusted through the floating mold by controlling the rotation direction and amount of rotation of the pressing shaft based on the pressure applied to the laminated core material in the clamped state.

The best mode for carrying out the present invention will be described below with reference to the drawings.
(Embodiment 1)
First, a first embodiment of the present invention will be described with reference to FIGS.
FIG. 1 is a perspective view showing a finished product, taking a rotor core for a motor as an example. As shown in this drawing, the rotor core is formed by laminating a plurality of core materials 10 processed into a plate shape, and these are integrated by a resin coating 14. The resin coating 14 is formed on both the upper and lower surfaces of the laminated core material 10, but only the upper surface side resin coating 14 is shown in FIG. 1. Moreover, both the resin coatings 14 are mutually connected through the through-hole 12 which is connected over the upper and lower surfaces of the core material 10 laminated | stacked so that it may demonstrate later.

  FIG. 2 is a cross-sectional view showing a mold opening state of a molding apparatus for molding a rotor core. FIG. 3 is a cross-sectional view showing a set state of the core material in the molding apparatus. FIG. 4 is a cross-sectional view showing a clamping state of the molding apparatus. The molds of the molding apparatus shown in these drawings are roughly classified into a fixed mold 20, a floating mold 30, and a movable mold 40. This molding apparatus is for molding the resin coating 14 on the upper and lower surfaces of the laminated core material 10.

  The fixed mold 20 has an internal space 22 that is open on both upper and lower surfaces, and a floating mold 30 is incorporated in the internal space 22. On the lower surface side of the fixed mold 20, a back plate 26 is provided with the internal space 22 closed. Further, on the upper surface side of the fixed mold 20, a portion excluding the open surface of the internal space 22 is a joint surface 23 with the movable mold 40.

  The floating mold 30 can reciprocate in the vertical direction with a predetermined stroke in the internal space 22 of the fixed mold 20. The upper part of the floating mold 30 is located in the open part of the internal space 22, and the upper surface thereof is a support surface 32 on which the laminated core material 10 is set. Further, a concave portion 34 for forming the resin coating 14 on the lower surface side is provided in the central portion of the support surface 32.

  The floating mold 30 includes a flange 36 at a lower portion thereof. A plurality of springs 38 (pressing means) are provided between the flange 36 and the back plate 26. Due to the elasticity of these springs 38, the floating mold 30 always receives an upward pressing force. In the mold open state, the upper surface of the flange 36 is received by the stepped stopper surface 24 in the internal space 22 (FIGS. 2 and 3), and the upward movement of the floating mold 30 is restricted.

  The movable mold 40 can be operated for mold clamping and mold opening with respect to the fixed mold 20 by a facility-side mold clamping mechanism (not shown) in the molding apparatus. The movable mold 40 has an internal space 42 opened at its lower surface, and the open surface of the internal space 42 is set to be larger than the upper open surface of the internal space 22 in the fixed mold 20. On the lower surface side of the movable mold 40, a portion excluding the open surface of the internal space 42 serves as a joint surface 43 that contacts the joint surface 23 of the fixed mold 20 during mold clamping. The back side (upper side) of the internal space 42 in the movable mold 40 is a pressing surface 46 for the core material 10 in the laminated state. Further, a concave portion 44 for molding the resin coating 14 on the upper surface side is provided in the central portion of the pressing surface 46.

Next, insert molding of the rotor core will be described.
In the mold open state of the molding apparatus, the floating mold 30 is pushed up by the elastic force of the spring 38, and the flange 36 is held at a position received by the stopper surface 24 in the internal space 22 of the fixed mold 20 (FIG. 2). , 3). Therefore, the laminated core material 10 is set on the support surface 32 of the floating mold 30 (FIG. 3). In this state, the outer periphery of the core material 10 in the stacked state is located inside the outer periphery of the support surface 32 of the floating mold 30.

  Next, the movable mold 40 is lowered toward the fixed mold 20, and the mold clamping state in which the joint surfaces 23 and 43 are brought into contact with each other is set (FIG. 4). By this clamping, the pressing surface 46 of the movable mold 40 comes into contact with the upper surface of the core material 10 in the laminated state, and the floating mold 30 is pushed down against the elastic force of the spring 38 according to the thickness of the entire core material 10. . In other words, the floating mold 30 at this time moves as a cushion by the pressing force of the spring 38 that is the pressing means, and absorbs the variation in the thickness of the entire core material 10 by the amount of movement. In other words, the movement of the floating mold 30 adjusts the mold partition line according to the thickness of the laminated core material 10 as a whole.

  In the mold clamping state, for example, a molten resin material is injected into the recess 44 from a resin injection port (not shown) provided in the movable mold 40. And the resin material which entered this recessed part 44 is also introduce | transduced also into the recessed part 34 of the floating type | mold 30 through the through-hole 12 of the core material 10 of a lamination | stacking state (FIG. 4). By curing the molten resin, the resin coating 14 is formed on the upper and lower surfaces of the laminated core material 10 and the core materials 10 are integrated. Thereafter, the movable mold 40 is raised and the mold is opened, and the rotor core is removed from the mold.

(Embodiment 2)
Next, a second embodiment of the present invention will be described with reference to FIG. In FIG. 5, members that are considered to have the same or equivalent configuration as those of the first embodiment are given the same reference numerals in the drawings, and redundant description is omitted. In the third and subsequent embodiments, the same description is not repeated.

  FIG. 5 is a cross-sectional view showing a clamping state of the molding apparatus. As shown in the drawing, the molding apparatus according to the second embodiment inserts a rotor core and the like by laminating a ring-shaped core material 10 with a punched center. As each core material 10 is ring-shaped, another floating mold 31 is disposed at the center of the floating mold 30, and the recess 44 of the movable mold 40 is also set in a ring shape.

  When the ring-shaped core material 10 is set in a laminated state on the support surface 32 of the floating mold 30, another floating mold 31 is in the center hole of each core material 10. The floating mold 30 receives an upward pressing force due to the elasticity of a spring 39 provided between the flange 37 and the back plate 26 of the fixed mold 20, and in the mold clamping state shown in the drawing. The end surface 33 on the opposite side (upper side) of the flange 37 is pressed against the central portion of the internal space 42 in the movable mold 40.

In the mold clamping state of FIG. 5, the molten resin is injected into the concave portion 44 of the movable die 40 and the concave portion 34 of the floating die 30 and hardened, so that the ring-shaped resin coating 14 is formed on the upper and lower surfaces of the laminated core material 10. The core material 10 is molded and integrated.
The springs 38 and 39 in the first and second embodiments are not limited to the coil springs shown in the drawings, and may be replaced with a disc spring or a gas spring.

(Embodiment 3)
Next, a third embodiment of the present invention will be described with reference to FIGS.
FIG. 6 is a cross-sectional view showing the mold opening state of the molding apparatus. FIG. 7 is a cross-sectional view showing a set state of the core material in the molding apparatus. FIG. 8 is a cross-sectional view showing a clamping state of the molding apparatus. As is apparent from these drawings, the molding apparatus of the third embodiment is basically the same as the molding apparatus of the first embodiment. However, as a pressing means for applying an upward pressing force to the floating mold 30, a plurality of cylinders 50 (hydraulic cylinders) are used instead of the springs 38, and the back plate 26 of the fixed mold 20 and the flange of the floating mold 30. 36.

  In the mold open state of the molding apparatus, no hydraulic pressure is applied to each cylinder 50 as the pressing means, and the floating mold 30 is lowered (FIG. 6). The laminated core material 10 is set on the support surface 32 of the floating mold 30 (FIG. 7), and the movable mold 40 is lowered toward the fixed mold 20 to be in a clamped state (FIG. 8). Thereafter, by applying a hydraulic pressure to the cylinder 50, the floating mold 30 is pushed up according to the thickness of the core material 10 as a whole. Variations in the thickness of the entire core material 10 are absorbed by the amount of movement of the floating mold 30 at this time.

(Embodiment 4)
Next, a fourth embodiment of the present invention will be described with reference to FIGS.
FIG. 9 is a cross-sectional view showing the mold opening state of the molding apparatus. FIG. 10 is a cross-sectional view illustrating a mold clamping state of the molding apparatus. FIG. 11 is a block diagram for controlling the pressing force. The pressing means in the fourth embodiment can control the pressing force on the floating mold 30.

  As shown in FIGS. 9 and 10, a housing 62 communicated with the internal space 22 is coupled to the fixed mold 20, and a pressing shaft 64 is incorporated in the housing 62. The pressing shaft 64 is engaged with the housing 62 with a screw, and can be moved back and forth by reciprocating rotation around the shaft center. Further, the upper end surface of the pressing shaft 64 is in contact with the lower surface of the flange 36 of the floating mold 30.

  A motor 68 (rotation drive means) is provided on the outer surface of the housing 62. The driving force of the motor 68 is transmitted by a timing belt 69 to a sprocket 66 provided on the axis of the pressing shaft 64. The floating mold 30 moves up and down by the up and down movement in the vertical direction accompanying the rotation of the pressing shaft 64.

  The movable mold 40 includes a pressure sensor 60 (detection means) that can detect the pressure applied to the core material 10 during mold clamping. A detection signal from the pressure sensor 60 is transmitted to the control means 70 shown in FIG. 11, and a control signal is transmitted from the control means 70 to the power supply circuit 72 of the motor 68 based on the detection signal. By driving the motor 68 based on this control signal, the pressing shaft 64 can be reciprocated.

  In the molding apparatus of the fourth embodiment, the core material 10 in a laminated state is set on the support surface 32 of the floating mold 30 in the mold open state (FIG. 9), and the movable mold 40 is lowered toward the fixed mold 20 to mold the mold. The tightening state is set (FIG. 10). By this clamping, the pressure applied to the laminated core material 10 is detected by the pressure sensor 60. Based on this detection signal, the motor 68 is driven as described above, and as a result, the pressing shaft 64 is reciprocally rotated. That is, the rotation direction and the amount of rotation of the pressing shaft 64 are controlled based on the pressure applied to the core material 10, and the pressure applied to the core material 10 through the floating mold 30 is finely adjusted. Therefore, the pressing force against the core material 10 in the laminated state can be adjusted to be constant regardless of the variation in the overall thickness.

Although the best mode for carrying out the present invention has been described above with reference to the drawings, this embodiment can be easily changed or modified without departing from the spirit of the present invention.
For example, the molding apparatus in the first to fourth embodiments is intended for a vertical type, but the present invention can be applied to a horizontal type molding apparatus. Further, the insert-molded product of the core material 10 in the laminated state is not limited to the rotor core, and may be a stator core, a yoke, or the like.

Perspective view showing the insert core Sectional view showing the mold opening state of the molding equipment Sectional view showing the core material set in the molding machine Sectional view showing the clamping state of the molding equipment Sectional drawing showing the clamping state of the molding apparatus in Embodiment 2 Sectional drawing showing the mold opening state of the shaping | molding apparatus in Embodiment 3 Sectional drawing showing the set state of the core material in the molding apparatus of Embodiment 3 Sectional drawing showing the clamping state of the molding apparatus in Embodiment 3 Sectional drawing showing the mold opening state of the shaping | molding apparatus in Embodiment 4 Sectional drawing showing the clamping state of the shaping | molding apparatus in Embodiment 4 Block diagram for controlling the pressing force

Explanation of symbols

10 Core material 20 Fixed type 30 Floating type 32 Support surface 38 Spring (pressing means)
40 Movable type 42 Internal space

Claims (4)

  A molding apparatus that molds an insert core by clamping a mold in a state where a plurality of core materials are stacked in an internal space constituted by a fixed mold and a movable mold, and injecting a molten resin into a part of the internal space. A floating type incorporated so as to be able to reciprocate in the stacking direction of the core material with respect to the fixed type, a support surface provided in the floating type so as to be able to support the core material in the stacked state, and a support surface with respect to the floating type And a pressing means for applying a predetermined pressing force from the opposite side of the molding apparatus.   The molding apparatus according to claim 1, wherein the pressing means is a spring provided between the fixed mold and the floating mold.   2. The molding apparatus according to claim 1, wherein the pressing means is a cylinder provided between the fixed mold and the floating mold. A molding apparatus that molds an insert core by clamping a mold in a state where a plurality of core materials are stacked in an internal space constituted by a fixed mold and a movable mold, and injecting a molten resin into a part of the internal space. The floating mold incorporated so that it can reciprocate in the stacking direction of the core material with respect to the fixed mold, the support surface provided in the floating mold so as to support the core material in the stacked state, and the reciprocating rotation around the axis A pressing shaft that can advance and retreat in the same direction as the floating mold and that is in contact with the floating mold on the opposite side of the support surface, a rotational drive means that can reciprocate the pressing shaft, and a core material in a stacked state A molding apparatus comprising: a detection unit capable of detecting a pressure applied to the rotation unit; and a control unit configured to control rotation drive of the rotation drive unit based on a detection signal from the detection unit.

Images