JP2010131781A - Method for producing insert-molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an insert-molded article which can carry out the working of a component to be inserted simultaneously with mold clamping, decrease the number of molding processes, curtail a production time, and reduce manufacturing costs without largely changing a conventional molding mechanism in insert molding. <P>SOLUTION: The method for manufacturing the insert-molded S article includes the first process in which at least one insert component P' to be worked is set in an upper mold 1 and/or a lower mold 2. the second process in which the upper mold 1 and the lower mold 2 are clamped, physical force generated by the mold clamping is applied to the insert component P' to be worked to change condition, and an insert attachment component P is made, and the third process in which a molten resin is packed in a cavity R formed by clamping the upper mold 1 and the lower mold 2, the insert attachment component P is brought into a mold condition, and the insert-molded article S is formed. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a method of manufacturing an insert-molded product that can simultaneously perform processing of a component to be inserted in a component insert-molding step.

When manufacturing a resin component, a cavity is created using an upper mold and a lower mold, and the resin is poured into the cavity and solidified.
At this time, when the insert mounting part is incorporated into the resin part, the insert mounting part is put into the mold by the conventional insert molding, and the resin is poured into the mold cavity to perform the molding. (For example, refer to Patent Document 1).

Patent Document 1 discloses a method for producing a two-layer molded article.
In the technique of this Patent Document 1, an attachment part (insert attachment part) is set on an upper mold constituting a molding die, the upper mold is lowered and clamped, and then a resin is filled in a cavity. Perform molding.
For this reason, the number of forming steps can be reduced, the manufacturing time can be shortened, and the manufacturing cost can be reduced.

JP 2004-167720 A

  However, according to the method of manufacturing a molded article described in Patent Document 1, the mounting part (insert mounting part) is positioned on the core material at the same time as the mold clamping, and is configured to be integrally formed simultaneously by insert molding. Although post-assembly of the attachment part (insert attachment part) is not required, it merely shows a so-called insert molding method that is generally performed.

  That is, according to the method described in Patent Document 1, it is only necessary to set a mounting part (insert mounting part) at a predetermined position, and it can be applied to those that do not require other processing. When other processing (press-fit processing, bending processing, cutting processing, punching processing, caulking processing, etc.) is necessary, it cannot be applied effectively, and a separate processing step is required, and the above effects are effectively achieved. I can't.

  An object of the present invention is to solve the above-mentioned problems, and in insert molding, processing of a part to be inserted (press-in process, bending process, cutting process, punching process) without greatly changing the conventional molding mechanism. Providing a method for manufacturing an insert molded product that can be performed simultaneously with mold clamping, reduce the number of molding steps, shorten the manufacturing time, and reduce the manufacturing cost. It is in.

  According to the method for manufacturing an insert-molded product according to the present invention, the above-described problem is a method for manufacturing an insert-molded product, in which at least one workpiece insert part is set in at least one of an upper mold and a lower mold. And the upper mold and the lower mold are clamped, and a physical force generated by the clamping of the upper mold and the lower mold is applied to the insert part to be processed, and the state of the insert part to be processed is changed. A second step of forming an insert mounting part, filling a cavity formed by clamping the upper mold and the lower mold with a molten resin, and placing the insert mounting part in a molded state, This is solved by performing the third step of forming the product.

Thus, in the present invention, when insert molding is performed, the physical force generated by clamping the upper die and the lower die is applied to the insert component to be processed, and the state of the insert component to be processed is changed. It can be a mounting part.
That is, the workpiece insert part can be processed into the insert mounting part simultaneously with the mold clamping.

Generally, when insert molding is performed, an insert mounting part is set in the upper mold or the lower mold.
In other words, it is necessary to set the upper mold or the lower mold after completely performing the processing until it does not require processing.
However, according to the method of manufacturing an insert-molded product according to the present invention, when the insert part to be processed at the stage before final processing is set in at least one of the upper mold and the lower mold, the process is performed by a physical force generated by mold clamping. The insert part is automatically machined into an insert mounting part (completely processed).

Therefore, there is no need to perform separate processing.
For this reason, the processing of parts to be inserted (for example, press-fitting, bending, cutting, punching, caulking, etc.) can be performed at the same time as clamping, reducing the number of molding steps and reducing manufacturing time. The manufacturing cost can be reduced while shortening.

  In the invention according to claim 1, the insert part to be processed is composed of a first assembly part and a second assembly part, and in the first step, the upper mold has the In addition to setting the first assembly part, the second assembly part is set to the lower mold, and in the second step, the physical force generated by clamping the upper mold and the lower mold is used. Preferably, the first part is configured to be press-fitted into the second part.

If comprised in this way, a press-fit process is performed by the physical force which arises by mold clamping as a process of the components inserted.
Therefore, the press-fitting process of the parts to be inserted can be performed simultaneously with the mold clamping, the number of molding processes can be reduced, the manufacturing time can be shortened, and the manufacturing cost can be reduced.

At this time, this processing method can be effectively applied to a rotating electrical machine.
That is, in the invention of claim 2, the first assembly component is a rotating shaft of a rotating electrical machine, and the second assembly component is a core member. In the second step, the core member The rotary shaft is press-fitted into a shaft through hole formed in the axial direction at the center of the mold, and after the second step, molten resin is put into a cavity formed by clamping the upper mold and the lower mold. The present invention is effectively applied to the manufacture of the armature of the rotating electrical machine by performing the third step of filling and making the insert mounting part in a molded state and setting the insulator in a molded state on the surface of the core material. be able to.

  Furthermore, in the invention according to claim 1, the workpiece insert part is composed of a first assembly part and a second assembly part, and in the first step, the upper die is attached to the upper mold. In addition to setting the first assembly part, the second assembly part is set to the lower mold, and in the second step, the physical force generated by clamping the upper mold and the lower mold is used. It is preferable that the first part is configured to be caulked with the second part.

If comprised in this way, crimping will be performed by the physical force which arises by mold clamping as a process of the components inserted.
Therefore, the caulking process of the inserted component can be performed simultaneously with the mold clamping, the number of molding process steps can be reduced, the manufacturing time can be shortened, and the manufacturing cost can be reduced.

  Further, in the invention according to claim 1, in the first step, the insert part to be processed is set in either the upper mold or the lower mold, and the upper mold and the lower mold are The mold on the side where the workpiece insert part is set is formed with a guide portion that supports the vicinity of the bending point of the workpiece insert part, and the other mold has the guide portion on the boundary of the bending point. A pressing portion disposed on the side opposite to the supporting side is formed, and the guide portion and the pressing member have a gap that exceeds the thickness of the insert part to be processed when the mold is clamped. In the second step, the insert component to be processed is pressed against the pressing member by the physical force generated by clamping the upper die and the lower die, and the guide Part The guided into the gap formed by the pressing member it is preferable that the inflection point is configured to flex as the boundary.

If comprised in this way, a bending process will be performed by the physical force which arises by mold clamping as a process of the components inserted.
Therefore, the bending process of the parts to be inserted can be performed simultaneously with the mold clamping, the number of forming processes can be reduced, the manufacturing time can be shortened, and the manufacturing cost can be reduced.

  Furthermore, in the first aspect of the present invention, in the first step, the insert part to be processed is set in either the upper mold or the lower mold, and the upper mold or the lower mold is A guide part that supports the vicinity of the cutting point of the workpiece insert part is formed on the mold on the side where the workpiece insert part is set, and the guide part is formed on the other mold with the cutting point as a boundary. A pressing portion disposed on the opposite side of the supporting portion, and the guide portion and the pressing member having a width not exceeding the thickness of the insert part to be processed when the mold is clamped. In the second step, the insert part to be processed is pressed against the pressing member by the physical force generated by the clamping of the upper mold and the lower mold. guide When the by shearing force caused by the pressing member is configured to be cut the cutting point as a boundary to be suitable.

If comprised in this way, a cutting process will be performed by the physical force which arises by mold clamping as a process of the components inserted.
Therefore, the cutting process of the parts to be inserted can be performed simultaneously with the mold clamping, the number of steps of the molding process can be reduced, the manufacturing time can be reduced, and the manufacturing cost can be reduced.

  In the first aspect of the present invention, in the first step, the insert part to be processed is set on the lower mold, and the lower mold has a punch point near the insert part to be processed. A scrap receiving portion is formed as a recess, and the upper die is provided with a punch for punching, and the punch is directly above the punching point and is inserted into the scrap receiving portion when the die is clamped. In the second step, the workpiece insert component is pressed against the punch by the physical force generated by clamping the upper die and the lower die, and the punching is performed. It is preferable to be configured to punch out points.

If comprised in this way, a punching process will be performed by the physical force which arises by mold clamping as a process of the components inserted.
Therefore, the stamping process of the inserted part can be performed simultaneously with the mold clamping, the number of molding process steps can be reduced, the manufacturing time can be shortened, and the manufacturing cost can be reduced.

According to the present invention, when insert molding is performed, a physical force generated by clamping the upper mold and the lower mold is applied to the insert part to be processed, and the state of the insert part to be processed is changed to obtain an insert mounting part. be able to.
That is, the workpiece insert part can be processed into the insert mounting part simultaneously with the mold clamping.
In other words, according to the method for manufacturing an insert-molded product according to the present invention, if the insert part to be processed at the stage before final processing is set in at least one of the upper mold and the lower mold, the physical force generated by clamping The workpiece insert part is automatically machined into an insert mounting part (completely processed).

Therefore, there is no need to perform separate processing.
For this reason, the parts to be inserted (for example, press-fitting, bending, cutting, punching, caulking, etc.) can be performed at the same time as clamping without greatly changing the conventional molding mechanism. The number of steps can be reduced, the manufacturing time can be shortened, and the manufacturing cost can be reduced.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Note that the configuration described below does not limit the present invention and can be variously modified within the scope of the gist of the present invention.
In this embodiment, insert molding can be performed simultaneously with mold clamping (insertion, bending, cutting, punching, caulking, etc.) in insert molding without greatly changing the conventional molding mechanism. In addition, the present invention relates to a method for manufacturing an insert-molded product that can reduce the number of steps of the forming step, reduce the manufacturing time, and reduce the manufacturing cost.

  FIG. 1 to FIG. 11 show an embodiment of the present invention, FIG. 1 is a process diagram showing a process for manufacturing an insert-molded product, and FIG. 2 is an explanatory diagram showing a process for manufacturing an insert-molded product with press-fitting. 3 is a reference diagram showing a conventional manufacturing process of an insert molded product with press-fitting, FIG. 4 is an explanatory diagram showing a manufacturing process of the insert molded product with a caulking process, and FIG. 5 is an illustration of the insert molded product with a caulking process. 6 is a reference diagram showing a conventional manufacturing process, FIG. 6 is an explanatory diagram showing a manufacturing process of an insert molded product with a bending process, FIG. 7 is a reference diagram showing a conventional manufacturing process of an insert molded product with a bending process, and FIG. FIG. 9 is a reference diagram showing a conventional manufacturing process of an insert-molded product with a cutting process, and FIG. 10 shows a manufacturing process of the insert-molded product with a punching process. Akirazu, 11 is a reference view showing a conventional manufacturing process of the insert-molded article with a punching process.

FIG. 1 is a process chart showing the manufacturing process of the insert molded product S according to this embodiment.
The insert molding according to the present embodiment is performed using a mold K having an upper mold 1 and a lower mold 2.
The upper mold 1 and the lower mold 2 have recesses formed in a predetermined shape, and a gap (cavity R) having the shape of a part to be molded by combining the upper mold 1 and the lower mold 2. A resin part is formed by pouring the softened resin into the cavity R and solidifying it.

In the present embodiment, by processing the upper mold 1 and the lower mold 2, further processing of the molded product (press-in process, bending process, cutting process, Punching, caulking, etc.) can be performed simultaneously.
For this reason, it is possible to reduce the number of steps of the forming step, shorten the manufacturing time, and reduce the manufacturing cost without greatly changing the conventional forming mechanism.

As shown in FIG. 1, in the manufacturing process of the insert molded product S according to the present embodiment, first, the insert part P ′ to be processed is put into the cavity R portion in the first process.
Next, in the second step, the upper mold 1 and the lower mold 2 are relatively brought closer to perform mold clamping.
At the time of mold clamping in the second step, various types of processing (press-in processing, bending processing, cutting processing, punching processing, caulking processing, etc.) of the insert part P ′ to be processed are performed simultaneously.
With this clamping force, the insert part P ′ to be processed is processed to become the insert mounting part P.
Details of these processes will be described later.

Thereafter, in the third step, the softened resin is introduced into the cavity R and then solidified and molded to produce the insert molded product S.
Further, in the fourth step, the insert molded product S is taken out from the mold K by opening the mold after the resin is solidified in the third step.

  Next, specific examples of various processes (press-in process, bending process, cutting process, punching process, caulking process, etc.) of the insert part P ′ to be processed at the time of mold clamping in the second step will be described in each example. To do.

(First embodiment)
First, the manufacturing process of the insert molded product S accompanied by press-fitting will be described with reference to FIGS.
FIG. 3 is a reference diagram of a conventional example showing a conventional manufacturing process for comparison.

As shown in FIG. 2A, first, the workpiece insert part P ′ is set on the upper mold 1 and the lower mold 2.
In this example, the processed insert part P ′ is initially divided into a press-fit part P11 and a press-fit part P12.
That is, a state where the press-fitting part P11 and the press-fitted part P12 are divided is a processed insert part P ′.
As shown in the figure, in this example, the press-fit component P11 is set on the upper die 1 and the press-fit component P12 is set on the lower die 2.
This corresponds to the first step of FIG.

Next, as shown in FIG. 2 (b), the upper mold 1 is moved closer to the lower mold 2 to perform mold clamping.
At this time, the press-fitting component P11 is press-fitted into the press-fitted component P12 by this clamping force (arrow direction: downward force toward the lower die 2).
That is, at the same time as the mold clamping, the press-fit component P11 is press-fitted into the press-fit component P12 to form the insert mounting component P1.
In this way, the press-fitting part P11 is press-fitted into the press-fitted part P12 so as to be integrated into the insert fitting part P1.
Therefore, a separate press-fitting process is unnecessary, and the press-fitting of the press-fitting part P11 into the press-fitted part P12 is completed simultaneously with the mold clamping.
The process of FIG. 2B corresponds to the second process of FIG.

Next, as shown in FIG. 2C, the cavity R is filled with a resin and molded.
This step corresponds to the third step in FIG.
Thereafter, after the resin is solidified, the insert molded product S is opened and taken out from the mold K to complete a series of molding.

On the other hand, in the conventional example shown in FIG. 3, the insert mounting part P1 needs to be completed when the insert mounting part P1 in FIG.
That is, before the step of FIG. 3A, it is necessary to perform a press-fitting process of press-fitting the press-fitting part P11 into the press-fitted part P12 to form the insert mounting part P1.

As described above, in the conventional example, after the insert mounting part P1 is set, it is necessary to similarly perform the mold clamping process of FIG. 3B and the molding process of FIG.
That is, in the manufacturing method of the insert molded product S according to the present embodiment, the number of processes is larger than that of forming the insert molded product S, which is disadvantageous in terms of manufacturing time and manufacturing cost.

In addition, this example can be effectively applied when manufacturing the armature of a rotary electric machine.
In this case, the press-fit component P11 is a rotating shaft, and the press-fit component P12 is a core member.
The core member is a known member provided in a rotating electrical machine, and is formed by laminating a plurality of core sheets each having a through hole formed in the center.

In this case, in the second step, the shaft through-hole formed in the axial direction at the center of the core member that is the press-fit component P12 (the through-hole formed in the core sheet central portion overlapped in a communicating state). The rotary shaft that is the press-fitting part P11 is press-fitted.
In this example, the armature corresponds to the insert mounting part P1.
Subsequent to the second step, a third step is performed in which the cavity R is filled with a molten resin and the insert mounting part P1 is molded.
At this time, the insulator may be molded on the surface of the core material.

(Second embodiment)
Next, a manufacturing process of the insert molded product S accompanied by caulking will be described with reference to FIGS. 4 and 5.
FIG. 5 is a reference diagram of a conventional example showing a conventional manufacturing process for comparison.

As shown in FIG. 4A, first, the workpiece insert part P ′ is set on the upper mold 1 and the lower mold 2.
In this example, the workpiece insert part P ′ is initially divided into a caulking part P21 and a caulking part P22.
That is, a state where the caulking part P21 and the caulking part P22 are divided is the processed insert part P ′.
As shown in the figure, in this example, the caulking part P21 is set on the upper mold 1 and the caulking part P22 is set on the lower mold 2.
This corresponds to the first step of FIG.

Next, as shown in FIG. 4B, the upper mold 1 is moved closer to the lower mold 2 to perform mold clamping.
At this time, the caulking part P21 is caulked to the caulking part P22 by this clamping force (arrow direction: downward force toward the lower die 2).
That is, simultaneously with the mold clamping, the caulking part P21 is caulked to the caulking part P22 to form the insert mounting part P2.
Thus, the caulking part P21 is caulked with the caulking part P22 so as to be integrated into an insert mounting part P2.
Therefore, there is no need for additional caulking, and simultaneously with this mold clamping, the caulking of the caulking part P21 to the caulking part P22 is completed.
The process of FIG. 4B corresponds to the second process of FIG.

Next, as shown in FIG. 4C, the cavity R is filled with a resin and molded.
This step corresponds to the third step in FIG.
Thereafter, after the resin is solidified, the insert molded product S is opened and taken out from the mold K to complete a series of molding.

On the other hand, in the conventional example shown in FIG. 5, the insert mounting part P2 needs to be completed when the insert mounting part P2 in FIG.
That is, before the step of FIG. 4A, it is necessary to perform a caulking process in which the caulking part P21 is caulked to the caulking part P22 to form the insert mounting part P2.
Thus, after setting the insert attachment part P2, it is necessary to perform the mold clamping process of FIG. 4B and the molding process of FIG. 4C in the same manner.
Therefore, in the method for manufacturing the insert-molded product S according to the present embodiment, the number of processes is larger than when the insert-molded product S is formed, which is disadvantageous in terms of manufacturing time and manufacturing cost.

(Third embodiment)
Next, a manufacturing process of the insert molded product S accompanied by bending will be described with reference to FIGS.
FIG. 7 is a reference diagram of a conventional example showing a conventional manufacturing process for comparison.
As shown in FIG. 6A, first, the workpiece insert part P ′ is set on the lower mold 2.
In this example, the processed insert part P ′ is configured as a bent part P31.
As shown in the figure, in this example, a bent part P31 is set on the lower mold 2.
This corresponds to the first step of FIG.

Next, as shown in FIG. 6B, the upper mold 1 is moved closer to the lower mold 2 to perform mold clamping.
Further, a pressing portion 11 and a guide portion 12 are formed on the upper mold 1.
The pressing part 11 is configured to be movable in the vertical direction (the same direction as the direction in which the upper mold 1 moves) with respect to the upper mold 1.

The upper end of the pressing portion 11 (the side opposite to the side on which the lower mold 2 is disposed) is connected to the spring 13, and the other end side of the spring 13 (the side to which the pressing portion 11 is connected). The end on the opposite side: upper end) is fixed inside the upper mold 1.
The guide part 12 is a protrusion protruding downward from the upper mold 1 (on the side where the lower mold 2 is disposed), and is disposed away from the pressing part 11 by a thickness equal to or greater than the thickness of the part P31 to be bent. .
Further, a support portion 21 is disposed immediately below the pressing portion 11 of the lower mold 2.
The support portion 21 is disposed so as to be separated from the pressing portion 11 by the thickness of the bent part P31.

In this state, when the upper mold 1 is relatively moved close to the lower mold 2 and the mold clamping is performed, a part of the bent part P31 (a part disposed immediately below the pressing part 11) becomes a pressing part. 11 and the support portion 21.
At this time, due to the restoring force of the spring 13, a part of the part to be bent P <b> 31 (part disposed immediately below the pressing part 11) is pressed more firmly to the support part 21.
Further, since the guide portion 12 is lowered downward as it is, the end portion of the bent part P31 is pushed by the guide portion 12 to a gap formed between the side surface of the support portion 21 and the side surface of the guide portion 12. Bend along.

That is, at this time, the part to be bent P31 is bent by this clamping force (arrow direction: downward force toward the lower die 2).
In other words, simultaneously with mold clamping, the part to be bent P31 is bent to form the insert mounting part P3.
Therefore, a separate bending process is unnecessary, and the bending process of the bent part P31 is completed simultaneously with the mold clamping.
This step of FIG. 6B corresponds to the second step of FIG.

Next, as shown in FIG. 6C, the cavity R is filled with a resin and molded.
This step corresponds to the third step in FIG.
Thereafter, after the resin is solidified, the insert molded product S is opened and taken out from the mold K to complete a series of molding.

On the other hand, in the conventional example shown in FIG. 7, the insert mounting part P3 needs to be completed when the insert mounting part P3 in FIG. Or it is necessary to make a finished product by post-processing.
That is, before the step of FIG. 7A, it is necessary to perform a bending step of bending the bent component P31 to form the insert mounting component P3.
Thus, after setting the insert attachment part P3, it is necessary to similarly perform the mold clamping process of FIG. 7B and the molding process of FIG. 7C.
That is, in the manufacturing method of the insert molded product S according to the present embodiment, the number of processes is larger than that of forming the insert molded product S, which is disadvantageous in terms of manufacturing time and manufacturing cost.

(Fourth embodiment)
Next, with reference to FIG. 8 and FIG. 9, the manufacturing process of the insert molded product S accompanied by cutting will be described.
FIG. 9 is a reference diagram of a conventional example showing a conventional manufacturing process for comparison.
As shown in FIG. 8A, first, the workpiece insert part P ′ is set on the lower mold 2.
In this example, the workpiece insert part P ′ is configured as a part to be cut P41.
As shown in the figure, in this example, a part P41 to be cut is set on the lower mold 2.
This corresponds to the first step of FIG.

Next, as shown in FIG. 8 (b), the upper mold 1 is moved relatively close to the lower mold 2 to perform mold clamping.
Further, a pressing portion 11 and a guide portion 12 are formed on the upper mold 1.
The pressing part 11 is configured to be movable in the vertical direction (the same direction as the direction in which the upper mold 1 moves) with respect to the upper mold 1.
The upper end of the pressing portion 11 (the side opposite to the side on which the lower mold 2 is disposed) is connected to the spring 13, and the other end side of the spring 13 (the side to which the pressing portion 11 is connected). The end on the opposite side: upper end) is fixed inside the upper mold 1.

The guide part 12 is a protrusion protruding downward from the upper mold 1 (on the side where the lower mold 2 is disposed), and is disposed at a predetermined width from the pressing part 11.
Further, a support portion 21 is disposed immediately below the pressing portion 11 of the lower mold 2.
Although this support part 21 is spaced apart from the press part 11, this width | variety is comprised so that the thickness of the to-be-cut component P41 may not be exceeded.

In this state, when the upper mold 1 is relatively brought close to the lower mold 2 and the mold clamping is performed, a part of the part P41 to be cut (part disposed immediately below the pressing part 11) becomes the pressing part. 11 and the support portion 21.
At this time, due to the restoring force of the spring 13, a part of the part to be cut P <b> 41 (part disposed immediately below the pressing part 11) is pressed more firmly to the support part 21.
Further, the guide portion 12 is lowered as it is, but as described above, the distance between the support portion 21 and the pressing portion 11 (the distance between the two during the mold clamping) is smaller than the width of the member to be cut P41. Therefore, the shearing force works, and the part to be cut P41 is cut by the support part 21 and the pressing part 11.

That is, at this time, the part to be cut P41 is cut by the clamping force (arrow direction: downward force toward the lower die 2).
In other words, simultaneously with mold clamping, the part to be cut P41 is cut to form the insert mounting part P4.
Therefore, a separate cutting process is unnecessary, and the bending process of the part P41 to be cut is completed simultaneously with the mold clamping.
This step of FIG. 8B corresponds to the second step of FIG.

Next, as shown in FIG. 8C, the cavity R is filled with a resin and molded.
This step corresponds to the third step in FIG.
Thereafter, after the resin is solidified, the insert molded product S is opened and taken out from the mold K to complete a series of molding.

On the other hand, in the conventional example shown in FIG. 9, the insert mounting part P4 needs to be completed when the insert mounting part P4 of FIG. Or it is necessary to make a finished product by post-processing.
That is, before the step of FIG. 9A, it is necessary to perform a cutting process of cutting the part to be cut P41 to form the insert mounting part P4.
Thus, after setting the insert mounting part P4, it is necessary to similarly perform the mold clamping process of FIG. 9B and the molding process of FIG. 9C.
That is, in the manufacturing method of the insert molded product S according to the present embodiment, the number of processes is larger than that of forming the insert molded product S, which is disadvantageous in terms of manufacturing time and manufacturing cost.

(5th Example)
Next, a manufacturing process of the insert molded product S accompanied by punching will be described with reference to FIGS.
FIG. 11 is a reference diagram of a conventional example showing a conventional manufacturing process for comparison.
As shown in FIG. 10A, first, the workpiece insert part P ′ is set on the lower mold 2.
In this example, the processed insert part P ′ is configured as a punched part P51.
As shown in the drawing, in this example, a punched part P51 is set on the lower mold 2.
This corresponds to the first step of FIG.

Next, as shown in FIG. 10B, the upper mold 1 is moved closer to the lower mold 2 to perform mold clamping.
A punch 15 is formed on the upper die 1.
The punch 15 is configured to be movable in the vertical direction (the same direction as the direction in which the upper mold 1 moves) with respect to the upper mold 1.
The upper end of the punch 15 (the side opposite to the side on which the lower mold 2 is disposed) is connected to a spring 13, and the other end side of the spring 13 (opposite to the side to which the punch 15 is connected). Side end: upper end) is fixed inside the upper mold 1.
The punch 15 is a known punch, and a drilling blade is formed on the lower end surface (the surface on the side facing the lower mold 2).
In addition, a scrap receiving portion 25 is disposed immediately below the punch 15 of the lower mold 2.
The scrap receiving portion 25 is formed as a recess disposed immediately below the punch 15.

In this state, when the upper die 1 is relatively moved close to the lower die 2 and clamping is performed, a part of the punched component P51 (a portion disposed immediately below the punch 15) is moved by the punch 15. Punched out. Further, the punching scraps are collected by dropping into the scrap receiving portion 25 formed in the lower mold 2.
At this time, due to the pressing force of the spring 13, the force with which the punch 15 presses the punched part 51 becomes stronger.
That is, at this time, the punched part P51 is punched by the clamping force (arrow direction: downward force toward the lower die 2).
In other words, at the same time as the mold clamping, the punched part P51 is punched to form the insert mounting part P5.
Therefore, a separate punching process is unnecessary, and the punching process of the punched part P51 is completed simultaneously with the mold clamping.
The process of FIG. 10B corresponds to the second process of FIG.

Next, as shown in FIG. 10C, the cavity R is filled with a resin and molded.
This step corresponds to the third step in FIG.
Thereafter, after the resin is solidified, the insert molded product S is opened and taken out from the mold K to complete a series of molding.

On the other hand, in the conventional example shown in FIG. 11, the insert mounting part P5 needs to be completed when the insert mounting part P5 of FIG. Or it is necessary to make a finished product by post-processing.
That is, before the step of FIG. 11A, it is necessary to perform a punching process of punching the punched part P51 and forming the insert mounting part P5.
Thus, after setting the insert attachment component P5, it is necessary to similarly perform the mold clamping process of FIG. 11B and the molding process of FIG. 11C.
That is, in the manufacturing method of the insert molded product S according to the present embodiment, the number of processes is larger than that of forming the insert molded product S, which is disadvantageous in terms of manufacturing time and manufacturing cost.

Although five examples have been described above, the pattern is not limited to this as long as it does not depart from the spirit of the present invention.
For example, according to the shape to be formed, such as bending and punching at the same time, the above embodiments may be combined, or a device equipped with all of them may be used, and only unnecessary components may be removed from the mold K. You may be comprised so that it can be used.
Thus, there are various combination patterns.

  As described above, according to the present embodiment, since the insert mounting parts P1 to P5 can be processed simultaneously with the insert molding, it is not necessary to perform each processing step separately, and the number of steps can be reduced. Manufacturing time and manufacturing cost can be reduced.

It is process drawing which shows the manufacturing process of the insert molded product which concerns on one Embodiment of this invention. It is explanatory drawing which shows the manufacturing process of the insert molded product with the press-fitting process which concerns on one Embodiment of this invention. It is a reference figure which shows the conventional manufacturing process of the insert molded product accompanied by a press-fitting process. It is explanatory drawing which shows the manufacturing process of the insert molded product with the crimping process which concerns on one Embodiment of this invention. It is a reference drawing which shows the conventional manufacturing process of the insert molded product with a caulking process. It is explanatory drawing which shows the manufacturing process of the insert molded product accompanying the bending process which concerns on one Embodiment of this invention. It is a reference figure which shows the conventional manufacturing process of the insert molded product accompanying a bending process. It is explanatory drawing which shows the manufacturing process of the insert molded product with the cutting process which concerns on one Embodiment of this invention. It is a reference figure which shows the conventional manufacturing process of the insert molded product accompanying a cutting process. It is explanatory drawing which shows the manufacturing process of the insert molded product with the punching process which concerns on one Embodiment of this invention. It is a reference drawing which shows the conventional manufacturing process of the insert molded product with a punching process.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Upper mold | type, 11 ... Press part, 12 ... Guide part, 13 ... Spring, 15 ... Punch,
2 ... Lower mold, 21 ... Supporting part, 25 ... Waste receiver,
K ... Mold,
P, P1, P2, P3, P4, P5 ... Insert mounting parts,
P '... Insert parts to be processed
P11: Press-fit parts, P12: Press-fit parts, P21: Caulking parts, P22: Caulking parts, P31: Bending parts, P41: Cutting parts, P51: Punching parts,
R ... cavity,
S ... Insert molded product

Claims (7)

A method for manufacturing an insert molded article,
A first step of setting at least one workpiece insert part in at least one of the upper mold and the lower mold;
The upper mold and the lower mold are clamped, a physical force generated by clamping the upper mold and the lower mold is applied to the processed insert part, and the state of the processed insert part is changed, and the insert A second step for mounting parts;
Filling a cavity formed by clamping the upper mold and the lower mold with a molten resin, setting the insert mounting part in a molded state, and performing a third step of forming the insert molded product. A method for manufacturing an insert molded product. The workpiece insert part is composed of a first assembly part and a second assembly part,
In the first step, the first assembly part is set on the upper mold, and the second assembly part is set on the lower mold.
2. The method according to claim 1, wherein in the second step, the first part is press-fitted into the second part by a physical force generated by clamping the upper die and the lower die. Manufacturing method of insert molded product. The first assembly component is a rotating shaft of a rotating electrical machine, and the second assembly component is a core member,
In the second step, the rotary shaft is press-fitted into a shaft through hole formed in the axial direction in the center of the core member,
Following the second step, the cavity formed by clamping the upper mold and the lower mold is filled with molten resin, the insert mounting component is in a molded state, and the surface of the core material is insulated. 3. The method of manufacturing an insert-molded product according to claim 2, wherein a third step of making the mold into a molded state is performed. The workpiece insert part is composed of a first assembly part and a second assembly part,
In the first step, the first assembly part is set on the upper mold, and the second assembly part is set on the lower mold.
2. The method according to claim 1, wherein in the second step, the first part is caulked to the second part by a physical force generated by clamping the upper die and the lower die. Manufacturing method of insert molded product. In the first step, the insert part to be processed is set in either the upper mold or the lower mold,
Of the upper mold and the lower mold, the mold on the side on which the insert part to be processed is set is provided with a guide portion that supports the vicinity of the bending point of the insert part to be processed. A pressing portion disposed on the side opposite to the side supported by the guide portion with respect to the bending point is formed,
The guide part and the pressing member are configured to be arranged in parallel with a gap having a width exceeding the thickness of the workpiece insert part when the mold is clamped,
In the second step, the insert part to be processed is pressed by the pressing member by a physical force generated by clamping the upper die and the lower die, and is formed by the guide portion and the pressing member. 2. The method of manufacturing an insert-molded product according to claim 1, wherein the insert-molded product is bent with the bending point as a boundary. In the first step, the insert part to be processed is set in either the upper mold or the lower mold,
Of the upper mold and the lower mold, the mold on the side on which the insert part to be processed is set is provided with a guide portion that supports the vicinity of the cutting point of the insert part to be processed. A pressing portion disposed on the opposite side to the side supported by the guide portion at the cutting point is formed,
The guide part and the pressing member are configured to be arranged in parallel with a gap having a width not exceeding the thickness of the insert part to be processed when the mold is clamped,
In the second step, the work insert component is pressed against the pressing member by a physical force generated by clamping the upper mold and the lower mold, and shear is generated between the guide portion and the pressing member. 2. The method for manufacturing an insert-molded product according to claim 1, wherein the cutting is performed with a force as a boundary. In the first step, the workpiece insert part is set in the lower mold,
In the lower mold, in the vicinity of the punching point of the workpiece insert part, a scrap receiving part is formed as a recess, and the upper mold is provided with a punch for drilling,
The punch is located immediately above the punching point, and is disposed at a position where the punch is inserted into the scrap receiving part when the mold is clamped.
In the second step, the workpiece insert part is pressed against the punch by a physical force generated by clamping the upper die and the lower die, and the punching point is punched out. A method for producing the insert-molded product according to 1.

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