JP2011173243A - Molding method and molding system for multilayered molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding method and a molding system for a multilayered molding, capable of shortening a production cycle time of a secondary molding to be shorter than a molding cycle time in a longer side, when any of the molding cycle times of a primary molding and the secondary molding is long. <P>SOLUTION: This molding method for the multilayered molding is constituted to mold the secondary molding by layering a molten resin on one part or the whole face of a primary molding surface, includes a plurality of injection molding devices for molding the molding having the longer molding cycle time, is constituted to differ respectively molding cycle start times or molding cycle finish times thereof, and is constituted to control the respective molding cycle times of an injection molding device A for molding the molding of shorter molding cycle time and the plurality of injection molding devices, the molding cycle start times, and the molding cycle finish times, so as to make the production cycle time of the secondary molding shortest, and to make every cycle same. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a molding method and a molding system for a multilayer molded product in which a molten resin is laminated on a part or the entire surface of a primary molded product to mold a secondary molded product.

  Various molding methods such as those characterized by molds for molding, or those characterized by molding equipment, as molding methods for multilayer molded products consisting of various combinations of different materials, same materials, different colors, and same colors in resin molded products It has been known. One of them is a molding method in which a primary molded product formed by primary molding is inserted into a predetermined position of a mold and a molten resin is laminated on a part or the entire surface of the primary molded product to mold a secondary molded product. .

  In Patent Document 1, a first molten resin is poured into a first mold using a first injection molding machine and solidified, and injection molding is performed to obtain one or a plurality of resin molded products (primary molded products). A first step to produce, an intermediate step to set the resin molded product or resin molded assembly in the second mold of the second injection molding machine using an industrial robot, and remove the chuck and / or suction; Injection molding is performed by pouring the second molten resin into the gap between the second mold and the resin molded product or resin molded assembly using a molding machine, and solidifying the molten resin so as to be integrated with the resin molded product or resin molded assembly. And a second step of producing a two-color molded product (secondary molded product).

JP 2009-73151 A

  FIG. 13 shows a flow of a manufacturing method for manufacturing the two-color molded product of Patent Document 1 (“Method for manufacturing two-color molded product 91” described in Patent Document 1, paragraphs 0062 to 0063). FIG. 13 shows the contents of the corresponding part of Patent Document 1 from the description of Patent Document 1 in order to facilitate the comparison between Patent Document 1 and the present invention. Here, the arrows in FIG. 13 indicate the molding cycle of each molded product, and the arrows with white circles indicate the removal of the resin molded product L (primary molded product) from the first mold (first injection molding machine) and the second. Insertion into the mold (second injection molding machine), black circled arrows indicate discharge (removal) of the two-color molded product M (secondary molded product) from the second mold (second injection molding machine). .

  FIG. 13A shows a case where the molding cycle time M of the two-color molded product M (secondary molded product) is longer than the molding cycle time L of the resin molded product L (primary molded product). After the molding of the resin molded product L is completed, as indicated by the white circled arrow, the resin molded product L taken out from the first mold (first injection molding machine) by the industrial robot is used as it is as the second mold (second injection). Inserted into the molding machine). Subsequently, the molding of the two-color molded product M is started, and after the molding is completed, the two-color molded product M is dispensed by the ejector plate mounted on the movable mold of the second mold, as indicated by the black circled arrow, It is put into a bag or the like placed immediately below the payout portion of the movable mold of the second mold. Subsequently, the resin molded product L that has been molded in parallel is inserted into the second mold from which the two-color molded product M has been dispensed by the industrial robot. By repeating these steps, the two-color molded product M is continuously produced. In this embodiment, since the industrial robot is not used for taking out the two-color molded product M from the second mold, the two-color molded product M is dispensed from the second mold (takeout / black circle arrow), and resin molding is performed. The insertion of the product L into the second mold (arrow with white circle) can be continuously performed in this order.

  As shown in FIG. 13A, the production cycle time X of the final two-color molded product M (secondary molded product), that is, the next two-color molded product from the completion of molding of the previous two-color molded product M. The cycle time until the molding of M is completed is equal to the molding cycle time M even in the shortest case. Thus, in this embodiment, the production cycle time X of the two-color molded product M cannot be made shorter than the molding cycle time M of the two-color molded product M having a long molding cycle time.

  FIG. 13B shows a case where the molding cycle time L of the resin molded product L (primary molded product) is longer than the molding cycle time M of the two-color molded product M (secondary molded product). Since the basic molding process is the same, a detailed description is omitted. As shown in FIG. 13B, the production cycle time X of the two-color molded product M as the final product is equal to the molding cycle time L even in the shortest case. Therefore, also in this embodiment, the production cycle time X of the two-color molded product M cannot be made shorter than the molding cycle time L of the resin molded product L having a long molding cycle time.

  That is, in the manufacturing method of the two-color molded product of Patent Document 1, either the molding cycle time L of the resin molded product L (primary molded product) or the molding cycle time M of the two-color molded product M (secondary molded product). Even if this is long, the production cycle time X of the two-color molded product M cannot be made shorter than the molding cycle time of the molded product having the longer molding cycle time. In particular, when molding a multilayer molded product in which either one of the molding cycle time of the primary molded product and the cycle time of the secondary molded product is long and the time difference with the other molding cycle time is large, There is a problem from the viewpoint of productivity because the production cycle time of the molded product is restricted by the molding cycle time of the molded product having the longer one.

  The present invention has been made in view of the problems as described above. Specifically, even if either the molding cycle time of the primary molded product or the molding cycle time of the secondary molded product is long, It is an object of the present invention to provide a molding method and a molding system for a multilayer molded product that can make the production cycle time of a secondary molded product shorter than the molding cycle time of a molded product having a longer molding cycle time.

According to the first aspect of the present invention, as shown in claim 1, a primary molded product molded by a first injection molding apparatus to which a first mold is attached is converted into a second gold which is attached to a second injection molding apparatus. In a molding method of a multilayer molded product, which is inserted into a predetermined position of a mold, and a secondary molded product is molded by laminating a molten resin on a part or the entire surface of the primary molded product by the second injection molding device,
Comparing the molding cycle time of the primary molded product by the first injection molding device with the molding cycle time of the secondary molded product by the second injection molding device;
Equipped with multiple injection molding devices that mold the molded product with the longer molding cycle time,
The molding cycle start time or molding cycle completion time of each of the plurality of injection molding devices is made different so that the production cycle time of the secondary molded product molded by the second injection molding device is the shortest and the same every cycle. Further, the molding cycle time of the injection molding apparatus A that molds the molded product having the shorter molding cycle time, the molding cycle time of each of the plurality of injection molding apparatuses, and the injection molding apparatus A and the plurality of injection molding apparatuses, respectively. This is achieved by a method for molding a multilayer molded article, characterized in that the molding cycle start time and molding cycle completion time are controlled.

  In other words, a plurality of injection molding devices for molding a molded product with a longer molding cycle time are provided, and molding with a longer molding cycle time is performed by making the molding cycle start time or molding cycle completion time of each of these multiple units different. By partially overlapping the molding cycle times of the products and sequentially molding the molded product having the longer molding cycle time, the molding cycle time of these multiple units can be made shorter than the molding cycle time of one unit. Further, the molding cycle time of the injection molding apparatus A that molds the molded product having the shorter molding cycle time is linked to the molding cycle times of the plurality of units, and molding of each of the injection molding apparatus A and the plurality of injection molding apparatuses is performed. The cycle time, the molding cycle start time of each of the injection molding apparatus A and the plurality of injection molding apparatuses, and the molding cycle completion time are set to be the shortest in the production cycle time of the secondary molded product and the same every cycle. By being controlled, the production cycle time of the secondary molded product is formed with the longer molding cycle time regardless of which of the molding cycle time of the primary molded product and the molding cycle time of the secondary molded product is long. It can be made shorter than the molding cycle time of the product.

Next, as shown in claim 2, the primary molded product molded by the first injection molding apparatus to which the first mold is attached is placed at a predetermined position of the second mold attached to the second injection molding apparatus. In a molding method of a multilayer molded product, the molten resin is laminated on a part or the entire surface of the primary molded product by the second injection molding device, and a secondary molded product is molded.
Comparing the molding cycle time of the primary molded product by the first injection molding device with the molding cycle time of the secondary molded product by the second injection molding device;
An injection molding apparatus A for molding a molded product having a shorter molding cycle time;
Injection molding apparatus B and injection for molding a molded product having a longer molding cycle time, arranged substantially in parallel with the longitudinal direction of the injection molding apparatus A on both sides in a direction orthogonal to the longitudinal direction of the injection molding apparatus A Molding apparatus C;
Primary molded product holding means for taking out the primary molded product from the first mold and inserting it into a predetermined position of the second mold;
Secondary molded product holding means for taking out the secondary molded product from the second mold;
The primary molded product holding means and the secondary molded product holding means are supported, and the primary molded product is inserted between a fixed mold and a movable mold attached to each of the injection molding apparatuses A, B, and C. A molded article holding means and a secondary molded article holding means, each of which is inserted independently, and is provided with a molded article moving means for retracting,
The molding cycle start time or molding cycle completion time of each of the injection molding apparatuses B and C is made different so that the production cycle time of the secondary molded product molded by the second injection molding apparatus is the shortest and the same every cycle. Thus, the molding cycle time of each of the injection molding apparatuses A, B, and C and the molding cycle start time and molding cycle completion time of each of the injection molding apparatuses A, B, and C are controlled. Item 1 may be a method for forming a multilayer molded article.

  That is, two injection molding apparatuses (injection molding) for molding a molded article having a longer molding cycle time are used for one injection molding apparatus (injection molding apparatus A) for molding a molded article having a shorter molding cycle time. By arranging the devices B and C) and making these two molding cycle start times or molding cycle completion times different, the molding cycle time of the molding product with the longer molding cycle time partially overlaps, By alternately molding the longer molded product, the molding cycle time of these two units can be made shorter than the molding cycle time of one unit. Further, these two molding cycle times are linked to the molding cycle time of the other injection molding apparatus that molds the molded product having the shorter molding cycle time, and these three injection molding apparatuses A, B, and C are linked. Each molding cycle time, the molding cycle start time of each of these three injection molding apparatuses A, B and C, and the molding cycle completion time are the same as the production cycle time of the secondary molded product and the same every cycle. By controlling so that the molding cycle time of the primary molded product and the molding cycle time of the secondary molded product are long, the production cycle time of the secondary molded product is long. It can be made shorter than the molding cycle time of the other molded product. For that purpose, a primary molded product holding means and a secondary molded product holding means for independently holding the primary molded product and the secondary molded product, and these primary molded product holding means and secondary molded product holding means, However, in the state where the primary molded product and the secondary molded product are respectively held, each of the three injection molding apparatuses A, B and C is allowed to enter between the fixed mold and the movable mold. Therefore, there is a need for a molded article moving means for supporting the article to be retracted.

Further, as shown in claim 3, based on the controlled molding cycle time, molding cycle start time, and molding cycle completion time,
A step of taking out the primary molded product from the first mold by the primary molded product holding means;
A step of taking out the secondary molded product from the second mold by the secondary molded product holding means;
The time required for each of the primary molded product holding means to insert the second mold into the predetermined position of the second mold is corrected,
It is good also as a shaping | molding method of the multilayer molded product of Claim 2 which is controlled so that the production cycle time of the said secondary molded product becomes the shortest and the same every cycle.

  Thus, the time required for each step of the primary molded product holding means and the secondary molded product holding means is corrected, that is, the molding cycle time and the molding cycle start time of each injection molding device by the control or disturbance, etc. Even if the molding cycle completion time fluctuates, the production cycle time of the secondary molded product is controlled to be the shortest and the same every cycle by increasing or decreasing the time required for each process to absorb this. The

According to another aspect of the present invention, the primary molded product molded by the first injection molding apparatus to which the first mold is attached is attached to the second injection molding apparatus. In a molding apparatus for a multilayer molded product, which is inserted into a predetermined position of a two mold, and a secondary molded product is molded by laminating a molten resin on a part or the entire surface of the primary molded product by the second injection molding device,
Comparing the molding cycle time of the primary molded product by the first injection molding device with the molding cycle time of the secondary molded product by the second injection molding device;
An injection molding apparatus A for molding a molded product having a shorter molding cycle time;
Injection molding apparatus B and injection for molding a molded product having a longer molding cycle time, arranged substantially in parallel with the longitudinal direction of the injection molding apparatus A on both sides in a direction orthogonal to the longitudinal direction of the injection molding apparatus A Molding apparatus C;
Primary molded product holding means for taking out the primary molded product from the first mold and inserting it into a predetermined position of the second mold;
Secondary molded product holding means for taking out the secondary molded product from the second mold;
The primary molded product holding means and the secondary molded product holding means are supported, and the primary molded product is inserted between a fixed mold and a movable mold attached to each of the injection molding apparatuses A, B, and C. This is achieved by a molding system for a multilayer molded product including a molded product holding means for inserting and retracting the molded product holding means and the secondary molded product holding means independently.

  Such a molding system for a multilayer molded product enables the method for molding a multilayer molded product according to claim 1, which is a case where either the molding cycle time of the primary molded product or the molding cycle time of the secondary molded product is long. Even so, the production cycle time of the secondary molded product can be made shorter than the molding cycle time of the molded product having the longer molding cycle time.

  Next, as shown in claim 5, the first injection molding device is the injection molding device A, and the second injection molding device is the injection molding devices B and C. It may be a system.

  This is the case where the molding cycle time of the secondary molded products molded by the injection molding devices B and C is longer than the molding cycle time of the primary molded product molded by the injection molding device A. The primary molded product molded in step 1 is alternately supplied to two injection molding apparatuses B and C arranged on both sides of the injection molding apparatus A, and secondary molded products are produced alternately from these two units. It is.

  5. The multilayer molded product molding system according to claim 4, wherein the second injection molding apparatus is the injection molding apparatus A, and the first injection molding apparatus is the injection molding apparatuses B and C. It may be.

  This is the case where the molding cycle time of the primary molded product molded by the injection molding devices B and C is longer than the molding cycle time of the secondary molded product molded by the injection molding device A. And C are supplied alternately to one of the injection molding apparatuses A arranged between the injection molding apparatuses B and C, and a secondary molded product is produced from this one. It is. That is, the molding system of the multilayer molded product according to claim 4 can be configured regardless of which of the molding cycle time of the primary molded product and the molding cycle time of the secondary molded product is long.

  Next, as shown in claim 7, the molded article moving means is provided from a horizontal structure provided in a direction perpendicular to the longitudinal direction of the apparatus above the mold clamping apparatuses of the injection molding apparatuses A, B and C. A molding system for a multilayer molded article according to any one of claims 4 to 6 may be used.

  Thus, the primary molded product holding means and the secondary molded holding means are independent of the horizontal structure provided in the direction orthogonal to the longitudinal direction of the apparatus above the mold clamping devices of the injection molding apparatuses A, B and C. Thus, the molded product holding means can be moved in the shortest distance between the fixed mold and the movable mold attached to each injection molding apparatus.

  Next, as shown in claim 8, the molded product moving means moves between the molded product moving mechanism means AB that moves the molded product between the injection molding devices A and B, and the injection molded devices A and C. The molding system for a multilayer molded article according to claim 6, further comprising a molded article moving means AC for moving the molded article.

  When the second injection molding apparatus is the injection molding apparatus A and the first injection molding apparatus is the injection molding apparatuses B and C, the injection molding apparatus A and the injection molding apparatus A are in this way. And the molded product moving means AB and AC are divided and arranged between each of C and C, and the primary molded product and the secondary molded product are moved only between the respective injection molding apparatuses. A product molding system can be configured.

  Furthermore, as shown in claim 9, it is preferable that at least one of the molded article moving means AB and AC is an articulated robot.

  Thus, if at least one of the molded article moving means AB and AC is an articulated robot, at least one of the primary molded article take-out operation, the mold insertion operation, and the secondary molded article take-out operation is performed. The degree of freedom, position accuracy, and repeatability can be improved. Furthermore, if both of the molded article moving means AB and AC are articulated robots, it is possible to improve the freedom of movement, position accuracy and repeatability of both of them.

  Next, as shown in claim 10, at least one surface of the primary molded product is a resin molded product that requires design properties, and molding a multilayer molded product according to any one of claims 4 to 9 A system is preferred.

  When at least one surface of the primary molded product is a resin molded product that requires design properties, an injection compression molding method or an injection press molding method with excellent design transferability is adopted for the primary molding, and the shape of the molded product In many cases, either the molding cycle time of the primary molded product or the molding cycle time of the secondary molded product is long, and the time difference from the other molding cycle is large. Therefore, it greatly contributes to shortening of the production cycle time of the secondary molded product.

  11. The multilayer molded product molding system according to claim 4, wherein the primary molded product is a translucent resin molded product as shown in claim 11. Is preferred.

  Such a primary molded product is a resin molded product having translucency, for example, resin windows for vehicles, ships, aircrafts, display panels such as liquid crystal televisions, plasma televisions, liquid crystal monitors for personal computers, and automobile coupes. In the case of a tailgate (hatchback door) that is integrally molded including the resin window part of a vehicle model such as a hatchback or a wagon, it is required to reduce the distortion of the resin molded product having translucency of the primary molded product. For this reason, an injection compression molding method or an injection press molding method with little distortion after molding is often employed. That is, either the molding cycle time of the primary molded product or the molding cycle time of the secondary molded product is long, and the time difference from the other molding cycle time is large. It is important to contribute to shortening.

In the method for molding a multilayer molded product according to the present invention, a primary molded product molded by a first injection molding apparatus to which a first mold is attached is used as a predetermined for a second mold attached to the second injection molding apparatus. In a molding method of a multilayer molded product, which is inserted into a position and laminated with a molten resin on a part or the entire surface of the primary molded product by the second injection molding device to mold a secondary molded product,
Comparing the molding cycle time of the primary molded product by the first injection molding device with the molding cycle time of the secondary molded product by the second injection molding device;
Equipped with multiple injection molding devices that mold the molded product with the longer molding cycle time,
The molding cycle start time or molding cycle completion time of each of the plurality of injection molding devices is made different so that the production cycle time of the secondary molded product molded by the second injection molding device is the shortest and the same every cycle. Further, the molding cycle time of the injection molding apparatus A that molds the molded product having the shorter molding cycle time, the molding cycle time of each of the plurality of injection molding apparatuses, and the injection molding apparatus A and the plurality of injection molding apparatuses, respectively. Since the molding cycle start time and molding cycle completion time are controlled, it is possible to produce a secondary molded product regardless of whether the molding cycle time of the primary molded product or the molding cycle time of the secondary molded product is long. The cycle time can be made shorter than the molding cycle time of the molded product having the longer molding cycle time.

Moreover, the molding system of the multilayer molded product according to the present invention is a second mold in which a primary molded product molded by a first injection molding apparatus to which a first mold is attached is attached to a second injection molding apparatus. A multilayer molded product molding system in which a molten resin is laminated on a part of or the entire surface of the primary molded product by the second injection molding device to mold a secondary molded product,
Comparing the molding cycle time of the primary molded product by the first injection molding device with the molding cycle time of the secondary molded product by the second injection molding device;
An injection molding apparatus A for molding a molded product having a shorter molding cycle time;
Injection molding apparatus B and injection for molding a molded product having a longer molding cycle time, arranged substantially in parallel with the longitudinal direction of the injection molding apparatus A on both sides in a direction orthogonal to the longitudinal direction of the injection molding apparatus A Molding apparatus C;
Primary molded product holding means for taking out the primary molded product from the first mold and inserting it into a predetermined position of the second mold;
Secondary molded product holding means for taking out the secondary molded product from the second mold;
The primary molded product holding means and the secondary molded product holding means are supported, and the primary molded product is inserted between a fixed mold and a movable mold attached to each of the injection molding apparatuses A, B, and C. Since the molding system of the multilayer molded product is provided with the molded product holding means and the molded product moving means for inserting and retracting the molded product holding means and the secondary molded product holding means, respectively, the molding cycle time of the primary molded product and Even if the molding cycle time of the secondary molded product is long, the production cycle time of the secondary molded product can be made shorter than the molding cycle time of the molded product having the longer molding cycle time.

It is a figure which shows the multilayer molded article which concerns on Example 1 of this invention. 1 is a schematic plan view of a molding system for a multilayer molded article according to Example 1 of the present invention. It is a schematic sectional drawing from the YY arrow of FIG. It is a schematic longitudinal cross-sectional view of the mold clamping apparatus which showed the primary shaping | molding process which concerns on Example 1 of this invention. It is a schematic longitudinal cross-sectional view of the mold clamping apparatus which showed the secondary shaping | molding process which concerns on Example 1 of this invention. It is the figure which showed the flow of the shaping | molding method of the multilayer molded article which concerns on Example 1 of this invention. It is a figure which shows the multilayer molded article which concerns on Example 2 of this invention. It is the figure which showed the flow of the shaping | molding method of the multilayer molded article which concerns on Example 2 of this invention. It is a figure which shows the multilayer molded article which concerns on Example 3 of this invention. It is a schematic plan view of the shaping | molding system of the multilayer molded article which concerns on Example 3 of this invention. It is a schematic sectional drawing from the YY arrow of FIG. It is the figure which showed the flow of the shaping | molding method of the multilayer molded article which concerns on Example 3 of this invention. It is the figure which showed the flow of the manufacturing method which produces the 2 color molded product of patent document 1. FIG.

  Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings.

A first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a view showing a multilayer molded product according to Example 1 of the present invention. FIG. 1A is a plan view, and FIG. 1B is a cross-sectional view taken along line HH in FIG. Moreover, FIG.1 (c) is sectional drawing in the HH arrow of FIG.1 (a) which showed the cooling state of the resin window 1a which is a primary molded article, FIG.1 (d) is a secondary molded article. It is sectional drawing in the HH arrow view of Fig.1 (a) which showed the cooling state of the support part 1b of the resin window 1 with a support part. FIG. 2 is a schematic plan view of a molding system for a multilayer molded article according to Embodiment 1 of the present invention. FIG. 3 is a schematic sectional view taken along the line YY in FIG. FIG. 4 is a schematic longitudinal sectional view of the mold clamping device illustrating the primary molding process according to the first embodiment of the present invention. 4 (a) shows the state opened mold before molding, Fig. 4 (b) is at a position before the mold closing is movable mold 13a, held in place in a position obtained by slightly opening by a predetermined amount S _0, the injection unit 11 1 FIG. 4C shows the state where the next injection is performed, and FIG. 4D shows the state where the movable mold 13a is clamped to the mold closing position and the resin window 1a is compression-molded after the completion of the primary injection. FIG. The state in which the molded resin window 1a is taken out from the movable mold 13a by the primary molded product holding mechanism 40a after the solidification time has elapsed is shown. FIG. 5 is a schematic longitudinal sectional view of the mold clamping apparatus showing the secondary molding process according to the first embodiment of the present invention. FIG. 5A shows a state where the resin window 1a is inserted into the fixed mold 22a by the primary molded product holding means 40a before molding, and FIG. 5B shows that the movable mold 23a is closed to the mold closing position. 5 (c) shows a state where the secondary injection is performed from the injection unit 21, and FIG. 5 (d) shows a case where the molded resin window 1 with a support portion is a secondary molded product holding mechanism after the cooling and solidifying time has elapsed. 40b shows a state of being taken out from the fixed mold 22a. FIG. 6 is a diagram showing a flow of a molding method of a multilayer molded product according to Example 1 of the present invention. 6A shows the case where the molding cycle time ratio of the primary molded product and the secondary molded product is 1/3, FIG. 6B shows the same case of 1/2, and FIG. 6C shows the same 2/3. This case is shown.

  First, a multilayer molded product to be molded will be described. In Example 1, the resin window 1 with a support part (secondary molded product) as shown in FIG. The resin window 1 with a support part is a multilayer molded product in which a support part 1b is laminated by secondary molding around a flat resin window 1a (primary molded product) molded by primary molding. In recent years, the demand for such resin windows has increased as a substitute for glass windows in order to reduce the weight of vehicles, ships, aircrafts, and the like. In general, the resin window 1a, which is a primary molded product, is primarily molded by a molding method such as injection compression molding with less distortion after molding using a transparent or translucent polycarbonate resin or the like as a material. A part of the support is laminated by secondary molding, such as a window frame in which bosses, ribs and the like are integrated using colored polycarbonate resin or alloy resin.

  Here, there are many factors that determine the molding cycle time of the primary molded product and the molding cycle time of the secondary molded product, but the thickness of the molding layer and the cooling and solidification time of each molded product are one of the main factors. . For example, when the thicknesses of the molding layers of the primary molded product and the secondary molded product are substantially the same, the resin window 1a as the primary molded product can be cooled from both sides as shown in FIG. 1C (solid arrow). On the other hand, as shown in FIG. 1 (d), the laminated support part 1b of the resin window 1 with a support part, which is a secondary molded product, has a resin window 1a serving as a heat insulating layer. The cooling efficiency from the 1a side (broken arrows) is low, and cooling from only one side (solid arrows) is the main. Therefore, the cooling and solidification time of the secondary molded product is approximately doubled by simple calculation as compared with the primary molded product, and the molding cycle time follows this. However, since the relationship between the thicknesses of the molding layers of the primary molded product and the secondary molded product varies depending on the specifications and shape desired for the secondary molded product, which molding cycle time is generally longer I can't say that. Therefore, in Example 1, the resin with a support part that is a secondary molded product molded by the injection molding devices B and C from the molding cycle time of the resin window 1a that is the primary molded product molded by the injection molding device A The case where the molding cycle time of the window 1 is longer is assumed.

  Next, a molding system for multilayer molded products will be described. As shown in FIG. 2, an injection molding apparatus B (20) and an injection molding apparatus C (30) are arranged on both sides of the injection molding apparatus A (10). In Example 1, the first injection molding device for molding the resin window 1a (primary molded product) is molded from the injection molding device A (10) and the resin window 1 with support part (secondary molded product) based on the above-described assumption. The second injection molding devices to perform are the injection molding device B (20) and the injection molding device C (30). That is, the resin window 1a molded by the injection molding apparatus A (10) is alternately supplied to two injection molding apparatuses B (20) and C (30) arranged on both sides of the injection molding apparatus A (10). Thus, the resin window 1 with a support portion is produced alternately from these two units. And between the injection molding device A (10) and the injection molding device B (20), the secondary molded product carrying means 1 (50) is provided between the injection molding device A (10) and the injection molding device C (30). The secondary molded product carrying means 2 (60) is arranged in each. These secondary molded article conveying means is composed of a belt conveyor, a pallet conveying mechanism, and the like, and the resin window 1 with a supporting part conveyed from the injection molding apparatuses B (20) and C (30) to an arbitrary position outside the apparatus. Convey and deliver to the post-process outside the molding system.

  Injection molding apparatuses A (10), B (20), and C (30) are general-purpose injection molding apparatuses that do not have special functions. The injection molding apparatus A (10) will be described as a representative. A fixed mold 12a of a first mold that molds a primary molded product in combination with the movable mold 13a is attached to the fixed platen 12, and is fixed to a base portion (not shown). An injection unit 11 is disposed on the opposite side of the fixed mold 12a across the fixed platen 12 so as to be able to inject into the fixed mold 12a. The movable platen 13 is attached with a movable mold 13a of a first mold that forms a primary molded product in combination with the fixed mold 12a, and can be moved forward and backward by the mold clamping device 14 so as to face the fixed platen 12. It is attached to a base portion (not shown). The injection molding apparatuses B (20) and C (30) have basically the same structure, but the fixed molds 22a and 32a and the movable molds 23a and 33a attached to the respective parts insert the primary molded product. The second difference is only the second mold for molding the secondary molded product.

  And as shown in FIG. 3, it is orthogonal to the longitudinal direction of an injection molding apparatus above the fixed mold and movable mold of injection molding apparatus A (10), B (20), and C (30) opened. In the direction, the molded article moving means 40 is supported from the floor surface by the molded article moving means support column 40c. In the molded product moving means 40, the resin window 1a (primary molded product) is taken out from the first mold (injection molding apparatus A) and inserted into a predetermined position of the second mold (injection molding apparatuses B and C). The secondary molded product holding means 40a and the secondary molded product holding means 40b for taking out the resin window 1 with support portion (secondary molded product) from the second mold are independently attached, and the injection molding apparatus A (10 ), B (20) and C (30) are supported so as to be able to be inserted and retracted between the fixed mold and the movable mold. It goes without saying that the secondary molded product holding means 40b can transport the resin window 1 with a support site to both the secondary molded product carry-out means 1 (50) and the secondary molded product carry-out means 2 (60).

  Next, primary molding by the injection molding apparatus A (10) and secondary molding by the injection molding apparatuses B (20) and C (30) will be described. First, primary molding by the injection molding apparatus A (10) for molding the resin window 1a (primary molded product) having a short molding cycle time will be described.

FIG. 4 is a schematic longitudinal sectional view of the mold clamping device illustrating the primary molding process according to the first embodiment of the present invention. From the mold open state shown in FIG. 4A, the movable platen 13 is closed to the fixed platen 12 side by a mold clamping device (not shown). Here, as shown in FIG. 4 (b), in a position before the movable mold 13a is mold closing, is the position holding only slightly open position a predetermined quantity S _0, the enlarged mold cavity in this condition A transparent or translucent polycarbonate resin or the like is injected and filled from the injection unit 11.

After the injection completion of filling, or in conjunction with the injection filling, as shown in FIG. 4 (c), the movable mold 13a is closed mold to mold closing position from the only slightly open position a predetermined quantity S _0, the mold cavity A transparent or translucent polycarbonate resin or the like injected and filled therein is compression-molded by a clamping force. After the cooling and solidifying time of the resin window 1a in the mold cavity has elapsed, the movable mold 13a opens with the resin window 1a held by the movable mold 13a by a holding mechanism (not shown) built in the movable mold 13a. The primary molded product holding means 40a moved by the molded product moving means 40 is inserted between the fixed mold 12a and the movable mold 13a and molded as shown in FIG. 4 (d). The window 1a (primary molded product) is taken out from the movable mold 13a. Here, as the holding mechanism (not shown) built in the movable mold 13a and the holding mechanism of the resin window 1a of the primary molded product holding means 40a, various mechanisms are known, but a flat plate like the resin window 1a is used. When holding a molded product, a holding mechanism of the type that holds the object by sucking between the holding means and the holding object through a pad having airtightness so as not to damage the holding object is used. There are many. In addition, the primary molded product holding means 40a is not only moved in the direction perpendicular to the longitudinal direction of the injection molding apparatus by the molded product moving means 40, but also by a drive mechanism using a servo motor or a hydraulic cylinder (not shown). It goes without saying that the injection molding apparatus can be moved in the longitudinal direction between the fixed mold and the movable mold of the molding apparatus.

  In this way, by repeating the molding process of FIGS. 4A to 4D, the resin window 1a (primary molded product) is continuously molded from the injection molding apparatus A (10), and the primary molding is performed. The product is taken out by the product holding means 40a.

  Next, secondary molding by the injection molding apparatuses B (20) and C (30) in which the resin window 1 with a support part (secondary molded product) having a long molding cycle time is molded will be described. In the secondary molding by these injection molding apparatuses B (20) and C (30), the molding process itself is the same except that the molding cycle start time or the molding cycle completion time is different. Therefore, the injection molding apparatus B (20) is representative. Next, secondary molding will be described.

  FIG. 5 is a schematic longitudinal sectional view of the mold clamping device showing the secondary molding process according to the first embodiment of the present invention. As shown in FIG. 5 (a), the molded article moving means in a state where the resin window 1a (primary molded article) molded by the injection molding apparatus A (10) is held by the primary molded article holding means 40a. It is moved by 40 and inserted into a predetermined position of the fixed mold 22a in a state where the mold is opened. After the inserted resin window 1a is held by the fixed mold 22a by a molded product holding means (not shown) built in the fixed mold 22a, the primary molded product holding means 40a retracts out of the mold. Thereafter, as shown in FIG. 5B, the movable platen 23 is closed to the fixed platen 22 side by a mold clamping device (not shown).

  As shown in FIG. 5C, after the mold is closed, the mold formed between the resin window 1a (primary molded product) inserted into the mold and the fixed mold 22a. A colored polycarbonate resin or alloy resin is injected and filled from the injection unit 21 into the mold cavity, and a support portion 1b such as a window frame in which bosses and ribs are integrated is laminated around one surface of the resin window 1a. After the cooling and solidifying time of the laminated support part 1b has elapsed, the resin window 1 with support part (secondary molded product) is held on the fixed mold 22a by a holding mechanism (not shown) built in the fixed mold 22a. As shown in FIG. 5D, the movable mold 23a is opened and the secondary molded product holding means 40b moved by the molded product moving means 40 is placed between the fixed mold 22a and the movable mold 23a. The inserted and molded resin window 1 with a support part is taken out from the fixed mold 22a. Here, various mechanisms are known as a holding mechanism (not shown) built in the fixed mold B22a and a holding mechanism for the resin window 1 with a support part of the secondary molded product holding means 40b, but the resin window 1 with a support part is known. In the case of holding a flat plate shaped product such as that of the type that is held by sucking between the holding means and the holding object through a pad having airtightness so as not to damage the holding object and making it negative pressure A holding mechanism is often used. Further, the secondary molded product holding means 40b is not only moved in the direction orthogonal to the longitudinal direction of the injection molding apparatus by the molded product moving means 40, but also by a drive mechanism using a servo motor or a hydraulic cylinder (not shown). It goes without saying that the injection molding apparatus can be moved in the longitudinal direction between the fixed mold and the movable mold of the molding apparatus.

  Thus, by repeating the molding process of FIG. 5 (a) to FIG. 5 (d), the resin window 1 with support part (secondary molded product) is continuously molded from the injection molding apparatus B (20), It is taken out by the secondary molded product holding means 40b. In addition, as described above, the resin window 1 with a support part is continuously molded from the injection molding apparatus C (30) with different molding cycle start time or molding cycle completion time. As described above, the resin window 1 with a support portion, which is alternately molded from the injection molding apparatuses B (20) and C (30), is provided with the secondary molded product unloading means 1 (50) and 2 by the secondary molded product holding means 40b. It is carried out to the next molded product carrying means 2 (60) and carried out of the molding system.

  Next, a method for forming a multilayer molded product according to Example 1 of the present invention will be described. FIG. 6 is a diagram showing a flow of a molding method of a multilayer molded product according to Example 1 of the present invention. As described in the flow of the manufacturing method for manufacturing the two-color molded product of Patent Document 1, the arrows in FIG. 6 indicate the molding cycle of each molded product, and the white circled arrows indicate the resin window 1a (primary molded product). ) From the first mold (injection molding apparatus A) and inserted into the second mold (injection molding apparatuses B and C), and the black circled arrow indicates the number of the resin window 1 with support site (secondary molded product). 2 shows removal from a mold (injection molding apparatus B and C). In addition, symbols A, B, C, 50 and 60 in FIG. 6 denote injection molding apparatuses A (10), B (20), C (30), secondary molded product unloading means 1 (50) and secondary, respectively. The molded article carrying means 2 (60) is shown.

  In FIG. 6A, the molding cycle time of the resin window 1a (primary molded product) molded by the injection molding apparatus A (10) is 1, and the molding is performed by the injection molding apparatuses B (20) and C (30). This is a case where the molding cycle time of the resin window 1 with support site (secondary molded product) is assumed to be 3. (The molding cycle time ratio of the primary molded product and the secondary molded product is 1/3.) As shown in FIG. 6A, an injection molding apparatus B for molding the resin window 1 with a support portion having a long molding cycle time ( When the molding cycle start time (or molding cycle completion time) of 20) and C (30) is different by about 1.5, and the molding cycle of the injection molding apparatus A (10) is combined with these secondary moldings, The production cycle time X of the resin window 1 with a support part which is the final product, that is, the cycle time from the completion of the molding of the previous resin window 1 with a support part to the completion of molding of the next resin window 1 with a support part is 1.5. The resin window 1 with a support part having a long molding cycle time can be shortened to about ½ of the molding cycle time 3. Here, since insertion (indicated by white circles) of the resin window 1a from the injection molding apparatus A (10) to the injection molding apparatuses B (20) and C (30) does not overlap, one primary molding is performed. This can be implemented by the product holding means 40a. Moreover, taking out the resin window 1 with a support part from the injection molding apparatuses B (20) and C (30) performed continuously (arrows with black circles), and feeding to the injection molding apparatuses B (20) and C (30) Since the insertion of the resin window 1a (arrow with white circle) is performed by the independent secondary molded product holding means 40b and the primary molded product holding means 40a, the production cycle time of the resin window 1 with a support portion in this embodiment There is no problem with X.

  FIG. 6B shows a case where the molding cycle time of the resin window 1a (primary molded product) is assumed to be 1, and the molding cycle time of the resin window 1 with support portion (secondary molded product) is assumed to be 2. FIG. (The molding cycle time ratio of the primary molded product and the secondary molded product is ½.) As shown in FIG. 6B, an injection molding apparatus B for molding the resin window 1 with a support portion having a long molding cycle time ( When the molding cycle start time (or molding cycle completion time) of 20) and C (30) is made slightly different, and the molding cycle of the injection molding apparatus A (10) is combined with these secondary moldings, The production cycle time X of the resin window 1 with a support part, which is a product, is 1, and can be shortened to about ½ of the molding cycle time 2 of the resin window 1 with a support part having a long molding cycle time. Also in this embodiment, there is no problem in the production cycle time X of the resin window 1 with a support portion, as in FIG.

  FIG. 6C shows the case where the molding cycle time of the resin window 1a (primary molded product) is assumed to be 1, and the molding cycle time of the resin window 1 with a support part (secondary molded product) is assumed to be 1.5. (The molding cycle time ratio between the primary molded product and the secondary molded product is 2/3.) As shown in FIG. 6 (c), an injection molding apparatus B for molding the resin window 1 with a support portion having a long molding cycle time ( When the molding cycle start time (or molding cycle completion time) of 20) and C (30) is made slightly different, and the molding cycle of the injection molding apparatus A (10) is combined with these secondary moldings, The production cycle time X of the resin window 1 with a support part, which is a product, is 1, and can be shortened to approximately 2/3 of the molding cycle time 1.5 of the resin window 1 with a support part having a long molding cycle time. Also in this embodiment, there is no problem in the production cycle time X of the resin window 1 with a support portion, as in FIG.

  As shown in FIGS. 6A and 6B, when the molding cycle time ratio of the primary molded product and the secondary molded product is 1/2 or less, the production cycle time of the secondary molded product is set to the secondary molded product. The molding cycle time can be reduced to about ½. However, as shown in FIG. 6C, when the molding cycle time ratio between the primary molded product and the secondary molded product is larger than 1/2, the primary molded product having a short molding cycle time is continuously molded. However, a waiting time is generated in the secondary molding because the secondary molding is not in time. Therefore, although the production cycle time X of the secondary molded product can be made shorter than the molding cycle time of the secondary molded product having a long molding cycle time, the shortening rate becomes larger than ½. As described above, the present invention has a sufficient effect when the molding cycle time ratio between the primary molded product and the secondary molded product is 1/2 or less.

  Also, unlike the molding system of the present invention, when the primary molded product holding means 40a and the secondary molded product holding means 40b are not independent and integrated, the holding means itself is enlarged and the operation in the mold is not performed. The degree of freedom is reduced, and the resin window 1 with a support part is taken out from the injection molding apparatuses B (20) and C (30) continuously performed (arrows with black circles), and the injection molding apparatuses B (20) and C are performed. In the insertion of the resin window 1a into (30) (arrow with white circle), the first molded product is entered into the second mold while holding the primary molded product, and the primary molded product is inserted into the second mold, and the secondary mold is inserted. Taking out the molded product from the second mold continuously in the second mold, or taking out the secondary molded product from the second mold, taking out the primary molded product from the first mold, These operations in the mold are difficult or time consuming because it is necessary to insert them into the second mold. Rishite, secondary molded article of the production cycle time X becomes longer. Therefore, unless the molding cycle time ratio between the primary molded product and the secondary molded product is extremely large, the primary molded product holding means 40a and the secondary molded product holding means 40b, as in the molding system of the present invention, Must be independently insertable between molds.

  Next, Embodiment 2 of the present invention will be described with reference to the drawings.

  A second embodiment of the present invention will be described with reference to FIGS. FIG. 7 is a view showing a multilayer molded product according to Example 2 of the present invention. 7A is a plan view, and FIG. 7B is a cross-sectional view taken along the line II in FIG. 7A. FIG. 8 is a diagram showing a flow of a method for forming a multilayer molded product according to Example 2 of the present invention. 8A shows the case where the molding cycle time ratio of the secondary molded product and the primary molded product is 1/3, FIG. 8B shows the same case of 1/2, and FIG. 8C shows the same 2/3 case. This case is shown.

  First, a multilayer molded product to be molded will be described. In Example 2, a display panel 4 (secondary molded product) as shown in FIG. 7 is a molding target. The display panel 4 is a multilayer molded product in which a panel support portion 4b is laminated by secondary molding around the inner periphery of a flat panel portion 4a (primary molded product) molded by primary molding. In recent years, the demand for such display panels has been increasing in order to improve the design of liquid crystal televisions, plasma televisions, personal computer liquid crystal monitors, and the like. The material is the same as that of the resin window with the support part of Example 1 for both the primary molded product and the secondary molded product, and the same is that the molding method with less distortion after molding such as injection compression molding is adopted for the primary molding. is there.

  Unlike Example 1, Example 2 differs from Example 1 in the injection molding apparatuses B (20) and C (30) from the molding cycle time of the display panel 4, which is a secondary molded product molded by the injection molding apparatus A (10). The case where the molding cycle time of the panel part 4a which is a primary molded product to be molded is longer is assumed. That is, the second injection molding device for molding the display panel 4 (secondary molded product) is the injection molding device A (10), and the first injection molding device for molding the panel portion 4a (primary molded product) is the injection molding device B. (20) and the injection molding apparatus C (30), and the panel portion 4a molded by the injection molding apparatuses B (20) and C (30) is interposed between the injection molding apparatuses B (20) and C (30). The display panel 4 is produced by alternately supplying to one of the arranged injection molding apparatuses A (10). Therefore, in Example 2, the molding system configuration is the same as in FIGS. 2 and 3 shown in Example 1, but the primary molding process shown in FIG. 4 is not the injection molding apparatus A (10) but the injection molding apparatus. B (20) and C (30) are performed, and the secondary molding step shown in FIG. 5 is performed not by the injection molding apparatuses B (20) and C (30) but by the injection molding apparatus A (10), The multilayer molded product to be molded is different from the first embodiment.

  Next, a method for forming a multilayer molded product according to Example 2 of the present invention will be described. FIG. 8 is a diagram showing a flow of a molding method for a multilayer molded product according to Example 2 of the present invention. As described in the first embodiment, the arrows in FIG. 8 indicate the molding cycle of each molded product, and the white circled arrows indicate the first mold (injection molding apparatus B and the primary molded product) of the panel portion 4a. C) Removal and insertion into the second mold (injection molding apparatus A), black arrows indicate removal of the display panel 4 (secondary molded product) from the second mold (injection molding apparatus A). Yes. In addition, symbols A, B, C, 50 and 60 in FIG. 8 are injection molding devices A (10), B (20), C (30), secondary molded product unloading means 1 (50) and secondary, respectively. The molded article carrying means 2 (60) is shown.

  In FIG. 8A, the molding cycle time of the display panel 4 (secondary molded product) molded by the injection molding apparatus A (10) is 1, and the molding is performed by the injection molding apparatuses B (20) and C (30). This is a case where the molding cycle time of the panel portion 4a (primary molded product) is assumed to be 3. (The molding cycle time ratio between the secondary molded product and the primary molded product is 1/3.) As shown in FIG. 8A, an injection molding apparatus B (20) for molding the panel portion 4a having a long molding cycle time, and When the molding cycle start time (or molding cycle completion time) of C (30) is varied by about 1.5, and the molding cycle of the injection molding apparatus A (10) is combined with these primary moldings, the final product The production cycle time X of a certain display panel 4, that is, the cycle time from the completion of molding of the previous display panel 4 to the completion of molding of the next display panel 4 is 1.5, and the molding cycle of the panel portion 4a having a long molding cycle time. It can be shortened to about ½ of time 3. Here, since insertion (indicated by white circles) from the injection molding devices B (20) and C (30) of the panel portion 4a to the injection molding device A (10) does not overlap, one primary molding is performed. This can be implemented by the product holding means 40a. Further, the removal of the display panel 4 from the injection molding apparatus A (10) performed continuously (arrow with black circle) and the insertion of the panel portion 4a into the injection molding apparatus A (10) (arrow with white circle) are: Since it is implemented by the independent secondary molded product holding means 40b and the primary molded product holding means 40a, there is no problem in the production cycle time X of the display panel 4 in this embodiment.

  Further, in this embodiment, since the display panel 4 (secondary molded product) is molded by the injection molding apparatus A (10) disposed between the injection molding apparatuses B (20) and C (30), secondary molding is performed. The display panel 4 is molded by one secondary molded product delivery means by collecting the delivery of the display panel 4 on either one of the product delivery means 1 (50) and the secondary molded product delivery means 2 (60). You may carry it out of the system.

  FIG. 8B shows a case where the molding cycle time of the display panel 4 (secondary molded product) is assumed to be 1, and the molding cycle time of the panel portion 4a (primary molded product) is assumed to be 2. FIG. (The molding cycle time ratio between the secondary molded product and the primary molded product is 1/2.) As shown in FIG. 8B, an injection molding apparatus B (20) for molding the panel portion 4a having a long molding cycle time, and When the molding cycle start time (or molding cycle completion time) is different from that of C (30) by 1 and the molding cycle of the injection molding apparatus A (10) is combined with these secondary moldings, the final product is obtained. The production cycle time X of the display panel 4 is 1, and can be shortened to about ½ of the molding cycle time 2 of the panel portion 4a having a long molding cycle time. Also in this embodiment, there is no problem in the production cycle time X of the display panel 4 as in FIG.

  FIG. 8C shows a case where the molding cycle time of the display panel 4 (secondary molded product) is assumed to be 1, and the molding cycle time of the panel portion 4a (primary molded product) is assumed to be 1.5. (The molding cycle time ratio between the secondary molded product and the primary molded product is 2/3.) As shown in FIG. 8C, the injection molding apparatus B (20) for molding the panel portion 4a having a long molding cycle time, and When the molding cycle start time (or molding cycle completion time) is different from that of C (30) by 1 and the molding cycle of the injection molding apparatus A (10) is combined with these secondary moldings, the final product is obtained. The production cycle time X of the display panel 4 is 1, which can be shortened to about 2/3 of the molding cycle time 1.5 of the panel portion 4a having a long molding cycle time. Also in this embodiment, there is no problem in the production cycle time X of the display panel 4 as in FIG.

  As shown in FIGS. 8A and 8B, when the molding cycle time ratio between the secondary molded product and the primary molded product is 1/2 or less, the production cycle time of the secondary molded product is set to the secondary molded product. The molding cycle time can be reduced to about ½. However, as shown in FIG. 8 (c), when the molding cycle time ratio of the secondary molded product and the primary molded product is larger than 1/2, when the secondary molded product having a short molding cycle time is continuously molded, Since the molding of the primary molded product having a long molding cycle time is not in time, the production cycle time X of the secondary molded product can be made shorter than the molding cycle time of the secondary molded product having a long molding cycle time. Becomes larger than 1/2. As described above, the present invention has a sufficient effect when the molding cycle time ratio between the secondary molded product and the primary molded product is 1/2 or less.

  Next, Embodiment 3 of the present invention will be described with reference to the drawings.

  A third embodiment of the present invention will be described with reference to FIGS. FIG. 9 is a view showing a multilayer molded product according to Example 3 of the present invention. 9A is a perspective view, and FIG. 9B is a cross-sectional view taken along line JJ in FIG. 9A. FIG. 10 is a schematic plan view of a molding system for a multilayer molded product according to Embodiment 3 of the present invention. FIG. 11 is a schematic sectional view taken along the line YY in FIG. FIG. 12 is a diagram showing a flow of a method for forming a multilayer molded product according to Example 3 of the present invention. 12A shows the case where the molding cycle time ratio of the secondary molded product and the primary molded product is 1/3, FIG. 12B shows the same case of 1/2, and FIG. 12C shows the same 2/3 case. This case is shown.

  First, a multilayer molded product to be molded will be described. In Example 3, an automobile tailgate 7 (secondary molded product) as shown in FIG. The tailgate 7 is a tailgate (hatchback door) of a vehicle type such as an automobile coupe, hatchback, or wagon, and is an automobile member that is integrally formed including a resin window portion. A tailgate body 7b is laminated by secondary molding around a tailgate resin window 7a (primary molded product) molded by primary molding, and a door including such a resin window portion of an automobile is integrated. The demand for molded resin parts has been increasing in recent years in order to reduce the weight of automobiles and reduce the number of assembly steps. The material is the same as that of the resin window with the support part of Example 1 for both the primary molded product and the secondary molded product, and the same is that the molding method with less distortion after molding such as injection compression molding is adopted for the primary molding. is there. Compared to the multilayer molded products of Example 1 and Example 2, the size of the molded product is generally large for both the primary molded product and the secondary molded product.

  In the third embodiment, similarly to the second embodiment, the injection molding apparatuses B (20) and C (30) are obtained from the molding cycle time of the tailgate 7, which is a secondary molded product molded by the injection molding apparatus A (10). It is assumed that the molding cycle time of the tailgate resin window 7a, which is the primary molded product molded in step 1, is longer. That is, the second injection molding device for molding the tailgate 7 (secondary molded product) is the injection molding device A (10), and the first injection molding device for molding the tailgate resin window 7a (primary molded product) is injection molded. The tail gate resin window 7a formed by the injection molding apparatuses B (20) and C (30) is the injection molding apparatuses B (20) and C (30). ) Are alternately supplied to one of the injection molding apparatuses A (10), and the tailgate 7 is produced from this one.

  FIG. 10 is a schematic plan view of a molding system for a multilayer molded product according to Example 3 of the present invention, and FIG. 11 is a schematic cross-sectional view taken along the line XX of FIG. As described above, the second injection molding device for molding the tailgate 7 (secondary molded product) is the injection molding device A (10), and the first injection molding for molding the tailgate resin window 7a (primary molded product). The apparatuses are an injection molding apparatus B (20) and an injection molding apparatus C (30).

  Here, the difference from Example 2 of Example 3 other than the multilayer molded product to be molded is that between injection molding apparatuses A (10) and B (20), as shown in FIGS. Between the injection molding apparatuses A (10) and C (30), the molded article moving means are divided and arranged as in the molded article moving means AB (45) and the molded article moving means AC (46), respectively. It is a point which moves a primary molded product and a secondary molded product only between molding apparatuses. The molded article moving means AB (45) and the molded article moving means AC (46) are articulated robots, and are provided with a primary molded article holding means 40a and a secondary molded article holding means 40b at the tip of each robot arm, The tailgate resin window 7a (primary molded product) is taken out from the first mold (injection molding apparatus B or C), inserted into a predetermined position of the second mold (injection molding apparatus A), and from the second mold. The tailgate 7 (secondary molded product) is taken out and carried out to the secondary molded product carrying means 1 (50) and the secondary molded product carrying means 2 (60). Further, a circle centering on the molded article moving means AB (45) and the molded article moving means AC (46) in FIG. 10 indicates the maximum movable range of the tip of the robot arm of the articulated robot.

Between the injection molding apparatuses A (10) and B (20) and between the injection molding apparatuses A (10) and C (30), the molded article moving means AB (45) and the molded article moving means AC (46), respectively. If the molded article moving means is divided and arranged as described above, the overall height of the molding system can be reduced. In this case, however, the molded product moving means AB (45) and the molded product moving means AC (46) must be equipped with the primary molded product holding means 40a and the secondary molded product holding means 40b, respectively. In the first mold, the primary molded product holding means 40a and the secondary molded product holding means 40b of Example 1 are not independent and are integrated as described above. Although it is not necessary to enter, the holding means itself becomes large and the degree of freedom of operation in the mold is reduced.

When the primary molded product holding means 40a and the secondary molded product holding means 40b are not independent and integrated

  However, as in the third embodiment, by adopting an articulated robot for the molded article moving means AB (45) and the molded article moving means AC (46), the primary molded article is taken out and inserted into the mold. The degree of freedom, the positional accuracy, and the repeatability of the operation and the operation of taking out the secondary molded product can be improved. Further, an unillustrated auto tool changer (ATC / automatic tool changer) is provided at the tip of the robot arm of the articulated robot of the molded article moving means AB (45) and the molded article moving means AC (46), and each of the articulated articulated robots. If the primary molded product holding means 40a and the secondary molded product holding means 40b at the front end are automatically replaced for each process required by the robot, the problem that the holding means itself increases in size can be solved. In view of the effect of improving the freedom of movement, position accuracy and repeatability by the multi-joint robot, both the primary molded product and the secondary molded product are handled with large molded product dimensions as in Example 3. It is a preferable form.

  Next, a method for forming a multilayer molded product according to Example 3 of the present invention will be described. FIG. 12 is a diagram showing a flow of a molding method for a multilayer molded product according to Example 3 of the present invention. In the same manner as described in the second embodiment, the arrows in FIG. 12 indicate the molding cycle of each molded product, and the white circled arrows indicate the first mold (injection molding apparatus) of the tailgate resin window 7a (primary molded product). B and C) and insertion into the second mold (injection molding apparatus A), the black circled arrow indicates the removal of the tailgate 7 (secondary molded product) from the second mold (injection molding apparatus A). Show. In addition, symbols A, B, C, 50, 60, AB, and AC in FIG. 8 are the injection molding apparatuses A (10), B (20), C (30), and the secondary molded product carrying means 1 (50), respectively. ) Secondary molded product carrying means 2 (60), molded product moving means AB (45) and AC (46) are shown.

  In FIG. 12A, the molding cycle time of the tailgate 7 (secondary molded product) molded by the injection molding apparatus A (10) is 1, and molding is performed by the injection molding apparatuses B (20) and C (30). This is a case where the molding cycle time of the tailgate resin window 7a (primary molded product) is assumed to be 3. (The molding cycle time ratio between the secondary molded product and the primary molded product is 1/3.) As shown in FIG. 8A, an injection molding apparatus B (20 that molds the tailgate resin window 7a having a long molding cycle time. ) And C (30) with a molding cycle start time (or molding cycle completion time) different by about 1.5, and when the molding cycle of the injection molding apparatus A (10) is combined with these primary moldings, The production cycle time X of the tailgate 7 as a product, that is, the cycle time from the completion of the molding of the previous tailgate 7 to the completion of the molding of the next tailgate 7 is 1.5, and the tailgate resin window having a long molding cycle time. It can be shortened to about ½ of the molding cycle time 3 of 7a. Here, the insertion of the tailgate resin window 7a into the injection molding apparatus A10 from each of the injection molding apparatuses B (20) and C (30) (arrows with white circles) does not overlap, and the injection molding apparatus A (10). The tailgate 7 is taken out from the arrow (black arrow with arrows) and the tailgate resin window 7a is inserted into the injection molding apparatus A (10) (white arrow with arrows) are different from each other in the molded article moving means AB (45) and AC Therefore, there is no problem in the production cycle time X of the display panel 4 in this embodiment.

  Also, between the removal of the tailgate 7 from the injection molding apparatus A (10) (black circled arrow) and the insertion of the tailgate resin window 7a into the injection molding apparatus A (10) (white circled arrow), Since there is a margin of about 0.5, if possible in terms of cycle time, one of the articulated robots of the molded article moving means AB (45) and AC (46) is used and the same as in the second embodiment. By bringing the tailgate 7 into one side of either the secondary molded product carrying means 1 (50) or the secondary molded product carrying means 2 (60), the tail is formed by one secondary molded product carrying means. The gate 7 may be carried out of the molding system.

  FIG. 12B shows a case where the molding cycle time of the tailgate 7 (secondary molded product) is 1 and the molding cycle time of the tailgate resin window 7a (primary molded product) is 2. (The molding cycle time ratio between the secondary molded product and the primary molded product is 1/2.) As shown in FIG. 12B, the injection molding apparatus B (20 for molding the tailgate resin window 7a having a long molding cycle time. ) And C (30) with a molding cycle start time (or molding cycle completion time) slightly different from each other, and when the molding cycle of the injection molding apparatus A (10) is combined with these primary moldings, the final product The production cycle time X of the tailgate 7 is 1 and can be shortened to about ½ of the molding cycle time 2 of the tailgate resin window 7a having a long molding cycle time. Also in this embodiment, there is no problem in the production cycle time X of the tailgate 7 as in FIG.

  FIG. 12C shows the case where the molding cycle time of the tailgate 7 (secondary molded product) is assumed to be 1, and the molding cycle time of the tailgate resin window 7a (primary molded product) is assumed to be 1.5. (The molding cycle time ratio between the secondary molded product and the primary molded product is 2/3.) As shown in FIG. 12C, the injection molding apparatus B (20 for molding the tailgate resin window 7a having a long molding cycle time. ) And C (30) with a molding cycle start time (or molding cycle completion time) slightly different, and when the molding cycle of the injection molding apparatus A (10) is combined with these primary moldings, the final product The production cycle time X of the tailgate 7 is 1 and can be shortened to about 2/3 of the molding cycle time 1.5 of the tailgate resin window 7a having a long molding cycle time. Also in this embodiment, there is no problem in the production cycle time X of the tailgate 7 as in FIG.

  As shown in FIGS. 12A and 12B, when the molding cycle time ratio between the secondary molded product and the primary molded product is 1/2 or less, the production cycle time of the secondary molded product is set to the secondary molded product. The molding cycle time can be reduced to about ½. However, as shown in FIG. 12 (c), when the molding cycle time ratio of the secondary molded product and the primary molded product is larger than 1/2, when the secondary molded product having a short molding cycle time is continuously molded, Since the molding of the primary molded product having a long molding cycle time is not in time, the production cycle time X of the secondary molded product can be made shorter than the molding cycle time of the secondary molded product having a long molding cycle time. Becomes larger than 1/2. As described above, the present invention has a sufficient effect when the molding cycle time ratio between the secondary molded product and the primary molded product is 1/2 or less.

  The present invention can be implemented in various forms without being limited to the above-described embodiment without departing from the gist of the present invention. For example, in the first to third embodiments, the injection molding apparatuses A (10), B (20), and C (30) are horizontal injection molding apparatuses, and the injection units are arranged alternately. However, the injection unit of all the injection molding devices may be arranged and arranged, or each injection molding device may be a vertical injection molding device. Also, the primary molded product and the secondary molded product are left in either the fixed mold or the movable mold, or the primary molded product is either the fixed mold or the movable mold of the second mold. Whether to insert into the mold or the like should be appropriately selected based on the shape and size of the primary molded product and the secondary molded product. Further, as a molding method with less distortion after molding, in addition to the injection compression molding method shown in Example 1, an injection press molding method and the like are appropriately optimized based on the shape and size of the primary molded product. Should be selected.

  Otherwise, in the first embodiment, the molded article moving means 40 is supported from the floor surface by the molded article moving means support column 40c, but the molded article moving means is formed by the injection molding apparatuses A (10), B ( 20) and C (30) may be supported from each fixed platen, or may be supported from the ceiling. In the third embodiment, an articulated robot is used for both the molded article moving means AB (45) and the molded article moving means AC (46). However, the primary molded article holding means 40a and the secondary molded article are used. If the holding means can be shared by the same holding means, a form in which the existing take-out device is diverted to the molded article moving means AB (45) and AC (46), or one of them is an articulated robot and the other is an existing take-out It may be in the form of diverting the device.

  Furthermore, as in Example 3, the form in which the molded article moving means is divided and arranged is limited to the form in which secondary molding is performed by the central injection molding apparatus A (10). When the molding cycle time ratio with the molded product is extremely large, the secondary molding may be performed by the injection molding apparatuses B (20) and C (30) on both sides. When the molding cycle time ratio between the primary molded product and the secondary molded product is extremely large, which of the injection molding apparatuses A (10), B (20), and C (30) is used for secondary molding Regardless of this, one articulated robot including the primary molded product holding means 40a and the secondary molded product holding means 40b is movable with the fixed mold of each injection molding apparatus without dividing the molded product moving means. The mold may be moved along the horizontal structure of the molded article moving means 40 disposed above the opened mold.

  With the molding method and molding system for a multilayer molded product according to the present invention, the production cycle time of the secondary molded product is no matter which of the molding cycle time of the primary molded product and the molding cycle time of the secondary molded product is long. Can be made shorter than the molding cycle time of the molded product having the longer molding cycle time, and particularly when the ratio of the molding cycle time of the primary molded product and the secondary molded product is 1/2 or less, there is a sufficient effect. This is as explained. In addition, there is no need for a dedicated multi-color injection molding device or a special mold, and a combination of a general-purpose injection molding device with no special functions will produce a sufficient effect. Can be suppressed. In addition, the molding system of the present invention basically has the same configuration, and each injection molding apparatus can perform single-layer and single-color molding. Therefore, it is highly versatile as a molding system and has industrial utility value for manufacturers of resin molded products Extremely expensive.

1 Resin window with support part (secondary molded product)
4 Display panel (secondary molded product)
7 Tailgate (secondary molded product)
10 Injection molding equipment A
20 Injection molding equipment B
30 Injection molding machine C
40 Molded article moving means 40a Primary molded article holding means 40b Secondary molded article holding means 45 Molded article moving means AB
46 Molded article moving means AC

Claims (11)

The primary molded product molded by the first injection molding apparatus to which the first mold is attached is inserted into a predetermined position of the second mold attached to the second injection molding apparatus, and the second injection molding apparatus In a molding method of a multilayer molded product in which a molten resin is laminated on a part of or the entire surface of the primary molded product and a secondary molded product is molded.
Comparing the molding cycle time of the primary molded product by the first injection molding device with the molding cycle time of the secondary molded product by the second injection molding device;
Equipped with multiple injection molding devices that mold the molded product with the longer molding cycle time,
The molding cycle start time or molding cycle completion time of each of the plurality of injection molding devices is made different so that the production cycle time of the secondary molded product molded by the second injection molding device is the shortest and the same every cycle. Further, the molding cycle time of the injection molding apparatus A that molds the molded product having the shorter molding cycle time, the molding cycle time of each of the plurality of injection molding apparatuses, and the injection molding apparatus A and the plurality of injection molding apparatuses, respectively. A method for molding a multilayer molded article, wherein a molding cycle start time and a molding cycle completion time are controlled. An injection molding apparatus A for molding a molded product having a shorter molding cycle time;
Injection molding apparatus B and injection for molding a molded product having a longer molding cycle time, arranged substantially in parallel with the longitudinal direction of the injection molding apparatus A on both sides in a direction orthogonal to the longitudinal direction of the injection molding apparatus A Molding apparatus C;
Primary molded product holding means for taking out the primary molded product from the first mold and inserting it into a predetermined position of the second mold;
Secondary molded product holding means for taking out the secondary molded product from the second mold;
The primary molded product holding means and the secondary molded product holding means are supported, and the primary molded product is inserted between a fixed mold and a movable mold attached to each of the injection molding apparatuses A, B, and C. A molded article holding means and a secondary molded article holding means, each of which is inserted independently, and is provided with a molded article moving means for retracting,
The molding cycle start time or molding cycle completion time of each of the injection molding apparatuses B and C is made different so that the production cycle time of the secondary molded product molded by the second injection molding apparatus is the shortest and the same every cycle. Thus, the molding cycle time of each of the injection molding apparatuses A, B, and C and the molding cycle start time and molding cycle completion time of each of the injection molding apparatuses A, B, and C are controlled. Item 8. A method for forming a multilayer molded article according to Item 1. Based on the controlled molding cycle time, molding cycle start time, and molding cycle completion time,
A step of taking out the primary molded product from the first mold by the primary molded product holding means;
A step of taking out the secondary molded product from the second mold by the secondary molded product holding means;
The time required for each of the primary molded product holding means to insert the second mold into the predetermined position of the second mold is corrected,
3. The method for molding a multilayer molded product according to claim 2, wherein the production cycle time of the secondary molded product is controlled to be the shortest and the same every cycle. The primary molded product molded by the first injection molding apparatus to which the first mold is attached is inserted into a predetermined position of the second mold attached to the second injection molding apparatus, and the second injection molding apparatus In a molding system for a multilayer molded product in which a molten resin is laminated on a part or the entire surface of the primary molded product to mold a secondary molded product,
Comparing the molding cycle time of the primary molded product by the first injection molding device with the molding cycle time of the secondary molded product by the second injection molding device;
An injection molding apparatus A for molding a molded product having a shorter molding cycle time;
Injection molding apparatus B and injection for molding a molded product having a longer molding cycle time, arranged substantially in parallel with the longitudinal direction of the injection molding apparatus A on both sides in a direction orthogonal to the longitudinal direction of the injection molding apparatus A Molding apparatus C;
Primary molded product holding means for taking out the primary molded product from the first mold and inserting it into a predetermined position of the second mold;
Secondary molded product holding means for taking out the secondary molded product from the second mold;
The primary molded product holding means and the secondary molded product holding means are supported, and the primary molded product is inserted between a fixed mold and a movable mold attached to each of the injection molding apparatuses A, B, and C. A molding system for a multilayer molded product, comprising: a molded product moving means for inserting and retracting the molded product holding means and the secondary molded product holding means independently of each other.   5. The molding system for a multilayer molded product according to claim 4, wherein the first injection molding device is the injection molding device A, and the second injection molding device is the injection molding devices B and C.   5. The multilayer molded product molding system according to claim 4, wherein the second injection molding device is the injection molding device A, and the first injection molding device is the injection molding devices B and C.   5. The molded product moving means comprises a horizontal structure provided in a direction orthogonal to the longitudinal direction of the apparatus above the mold clamping apparatuses of the injection molding apparatuses A, B and C. Item 7. A molding system for a multilayer molded article according to Item 6.   The molded article moving means AB moves the molded article between the injection molding apparatuses A and B, and the molded article moving means AC moves the molded article between the injection molding apparatuses A and C. The molding system for a multilayer molded article according to claim 6, comprising:   9. The molding system for a multilayer molded product according to claim 8, wherein at least one of the molded product moving means AB and AC is an articulated robot.   The multilayer molded product molding system according to any one of claims 4 to 9, wherein at least one surface of the primary molded product is a resin molded product requiring design.   11. The molding system for a multilayer molded product according to claim 4, wherein the primary molded product is a resin molded product having translucency.

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