JP2019064274A - Molding method - Google Patents

Abstract

To provide a method for rotational molding of a molded product while defoaming a molding material.SOLUTION: The method for molding a product by rotation of a mold 100 contains: (i) a first step of filling the mold with a material, (ii) a second step of giving a rotation movement to the mold by using a stirrer 40 for agitation and defoaming the material, thereby rotational molding the product, (iii) a third step of starting the rotational molding from an open state of the mold, and (iv) a fourth step, after starting the rotational molding, of transition of the mold from the open state in rotation movement to a closed state. The mold contains a female mold 102 and a male mold 104; these female mold 102 and male mold 104, in the closed state, form a mold cavity of a predetermined shape together; these female mold and male mold, in the open state, are release from the opposite party respectively.SELECTED DRAWING: Figure 8

Description

The present invention relates to a method for rotational molding of a molded article while defoaming a molding material .

  It may be necessary to make high precision products (e.g. mechanical parts, electrical parts, electronic parts etc) by means of molding. The material used for the molding may be a mixture of a plurality of liquid materials, ie, a mixed material, which may include a liquid material exhibiting high viscosity.

  However, particularly when the materials used for molding are liquid mixed materials exhibiting high viscosity, when mixing and stirring a plurality of materials without special consideration, fine bubbles are generated in the materials in the process. May be mixed.

  Furthermore, when a highly viscous liquid material is injected into a mold, the material being injected may entrain air and be injected into the mold, and the air may remain as bubbles in the material. Also, a state in which the liquid material exhibiting high viscosity is not completely impregnated into the inner surface of the mold (for example, fine gaps, undercuts, etc.) (the material does not reach the entire inner surface of the mold) There is also a possibility that molding may be performed in the state).

  It is possible to defoam the mixed material prior to injection into the mold, but special considerations should be taken if the mixed material exhibits high viscosity even with at least one of the materials that make it up. Degassing the mixed material without it may leave bubbles in the mixed material.

  In any case, if air remains as air bubbles in the material in the mold or if the material does not completely impregnate the inner surface of the mold, a defect occurs in the molded product. For example, air bubbles (voids) may be present in the molded article, or the surface of the molded article may be locally lost.

  Therefore, conventionally, there has been a demand for performing agitation while effectively degassing the mixed material. In order to satisfy this demand, there is already known a technique in which a mixed material is accommodated in a container in a stirrer, and the container rotates with the stirrer under vacuum pressure while rotating the container (for example, see Patent Document 1). ).

Japanese Patent Application Laid-Open No. 11-104404

  Certainly, if the mixed material is stirred according to the method described in Patent Document 1, the mixed material is effectively defoamed in the stage before injecting the mixed material into the mold, and as a result, in the mixed material There are no bubbles present.

  However, when the mixed material is injected into the mold after stirring and defoaming, the material entrains air and is injected into the mold, and the air may remain as bubbles in the material, or the material There still remains the possibility of molding being carried out without complete impregnation of the entire inner surface of the mould.

  Therefore, in the conventional method, the possibility that air bubbles are present in the molded product or the surface of the molded product is locally lost can not be sufficiently reduced.

The present invention has been made to provide a novel method for rotational molding of a molded article while defoaming the molding material .

In order to solve the problem , according to an aspect of the present invention, there is provided a method of forming a product by rotating a forming die,
A first step of filling the mold with a material;
A second step of imparting a rotational movement to the mold, thereby agitating and degassing the material, and thereby rotationally molding the product;
A third step of starting the rotational molding from an open state of the mold;
A fourth step of causing the mold during the rotational movement to transition from the open state to the closed state after the start of the rotational molding;
There is provided a molding method comprising:

Further , according to one aspect of the present invention, the synthetic resin material is defoamed by rotating the mold having the cavity having the target product shape in a state of being filled with the liquid synthetic resin material, and the synthetic resin is A method of forming a product using a material,
A first step of filling the mold with the synthetic resin material;
A second step of disposing the mold in a vacuum chamber of a housing of a stirrer in a state in which the mold is pre-filled with the synthetic resin material in the first step;
A third step of driving the agitator to impart planetary motion to the mold in the vacuum chamber, thereby rotationally forming the product while stirring and defoaming the synthetic resin material;
The forming method is provided, wherein the planetary motion is generated by driving the agitator such that the forming die is revolved around a revolving axis and is rotated around a rotation axis inclined with respect to the revolving axis. Ru.

According to another aspect, there is provided a method of defoaming and molding a synthetic resin cap that is generally hollow hemispherical,
A first step of stirring and defoaming the molding material in the container by charging the molding material of the cap into the container and imparting a planetary motion to the container;
The stirred and defoamed molding material is introduced into the cavity of a molding unit having a female mold and a male mold, and the molding material in the cap is stirred and defoamed by applying planetary motion to the molding unit. A second step of rotational molding the cap,
There is provided a cap molding method comprising:

According to another aspect, there is provided a method of defoaming and molding a synthetic resin cap that is generally hollow hemispherical,
A first step of stirring and defoaming the molding material in the container by charging the molding material of the cap into the container and imparting a planetary motion to the container;
The stirring and defoaming molding material is put into a mold, and planetary motion is applied to the mold to rotationally mold the cap while stirring and defoaming the molding material in the mold. There is provided a cap molding method comprising the steps of

  Preferably, the first step includes the step of applying the planetary motion to the container while the container is under vacuum pressure.

  Preferably, the second step includes the step of applying the planetary motion to the mold unit while the mold unit is under a vacuum pressure.

  Preferably, the second step includes the step of selectively performing the relative approach and the relative separation of the mold units in response to an external force acting on the mold units.

According to another aspect of the present invention, among fasteners to be fastened to a member to be fastened, in a fastening state with the member to be fastened, the fastener should be attached to a fastener exposed portion exposed from the surface of the member to be fastened A method of manufacturing a cap,
The cap is
A hollow hemispherical synthetic resin shell;
And a recess defined by the inner surface of the shell so as to form a hemisphere inside the shell;
The method is
A preparation step of preparing a sealant prior to mounting the cap on the exposed portion of the fastener,
The sealant is
(A) A thermosetting resin which cures when heated, and which once cured, does not restore its properties even if the temperature decreases,
(B) If frozen when not fully cured, the sealant freezes and then heated and thawed, the flowability of the sealant is restored and the curing of the sealant is resumed And those having the property of
Filling the sealant into the recess in a flowable state because curing of the sealant is not completed;
Freezing the cap filled with the sealant, thereby freezing the sealant;
And thawing and drying steps of thawing the cap filled with the frozen sealant and drying the cap to prevent condensation of the cap upon thawing by blowing air onto the cap. A method of making a sealant filled cap is provided.

According to still another aspect of the present invention, among fasteners fastened to a member to be fastened, the fastener is attached to a fastener exposed portion exposed from the surface of the member to be fastened in a fastening state with the member to be fastened A method of manufacturing a cap to be manufactured and attaching the manufactured cap to the exposed portion of the fastener,
The cap is
A shell portion made of synthetic resin generally in a hollow hemispherical shape;
And a recess defined by the inner surface of the shell portion to form a generally hemispherical shape therein;
The method is
A preparation step of preparing a sealant prior to mounting the cap on the exposed portion of the fastener,
The sealant is
(A) A thermosetting resin which cures when heated, and which once cured, does not restore its properties even if the temperature decreases,
(B) If frozen when not fully cured, the sealant freezes and then heated and thawed, the flowability of the sealant is restored and the curing of the sealant is resumed And those having the property of
Filling the sealant into the recess in a flowable state because curing of the sealant is not completed;
Freezing the cap filled with the sealant, thereby freezing the sealant;
A defoaming step of defoaming the sealant prior to the freezing;
When the cap filled with the frozen sealant arrives at the work site, the cap is heated in a state of being filled with the sealant, thereby thawing the sealant, whereby the sealant is liquefied A thawing process that is fluid again,
Drying the thawed cap, thereby removing condensation generated on the cap by the thawing;
The dried cap is attached to the fastener exposed portion such that the gap between the cap and the fastener exposed portion is filled with a sealant that fills the cap and having flowability. There is provided a sealant-filled cap manufacturing and mounting method including the mounting step.

  In one embodiment of this method, the degassing step comprises degassing the sealant before the sealant is filled into the recess. In another embodiment, the degassing step includes the step of degassing the sealant while the recess is filled with the sealant.

  The following aspects are obtained by the present invention. Each aspect is divided into sections, each section is given a number, and is described in a form in which the numbers of other sections are cited as necessary. This is to facilitate the understanding of some of the technical features that the present invention can adopt and combinations thereof, and the technical features that the present invention can adopt and combinations thereof are limited to the following embodiments. It should not be interpreted as That is, it should be understood that the technical features described in the present specification, which are not described in the following embodiments, can be appropriately extracted and adopted as the technical features of the present invention.

  Furthermore, describing each section in a form that refers to the number of another section does not necessarily prevent the technical features described in each section from being separated and independent from the technical features described in the other section. It is not meant to be understood, and it should be construed that it is possible to make the technical features described in each section independent as appropriate depending on their properties.

(1) Using a mold unit having a female mold and a male mold that selectively switch between a close contact state and a non close contact state to form a cavity having a predetermined shape, from a mixed liquid material, a synthetic resin A method of forming a product made of
Filling the cavity with the material;
At least a female mold of the mold units is disposed in a stirrer with the cavity filled with the material, and the stirrer causes the at least female mold to revolve around a rotation axis under vacuum pressure. An agitation defoaming step of causing the material to defoam while stirring in the cavity, thereby rotating the material about a rotation axis eccentric to the rotation axis while causing the material to rotate;
Curing the material in the mold unit.

  According to this molding method, at least the female mold of the mold unit is eccentric to the revolving axis while being revolved around the revolving axis under vacuum pressure in a state that the cavity is filled with the material. It is rotated around the rotation axis. Thereby, the material is defoamed while being stirred in the mold unit cavity.

  Furthermore, according to this molding method, at least the female mold is given a combined motion (planetary motion) of rotation and revolution by a stirrer while the cavity is filled with the material. Impregnation on the entire surface is promoted.

  Therefore, according to this molding method, it becomes easy to mold the product so that air bubbles are not present in the molded product and the surface of the molded product is not locally damaged.

(2) The curing step is
A molding method according to item (1), including the step of curing the material in the cavity by heating the entire mold unit.

(3) The filling step is performed to fill the female mold with the material in a state where the male mold is not in close contact with the female mold.
The stirring and defoaming step is
The mold filled with the material in the filling step is disposed in the stirrer in a state where the female mold is not attached to the female mold, and the whole female mold is placed under the vacuum pressure by the stirrer. A pre-stirring defoaming step of defoaming while stirring the material in the female mold while revolving about the rotation axis while revolving around a rotation axis;
After completion of the pre-stirring defoaming step, the male die is attached to the female die, thereby assembling the mold unit;
A main stirring and defoaming step of rotating the whole of the assembled mold unit while revolving it by the stirrer and thereby degassing the material while stirring again in the cavity of the mold unit; The shaping | molding method as described in (1) or (2) term containing.

  According to this molding method, prior to stirring and degassing the material while the mold is in close contact with the female mold in the mold unit by the stirrer, the same or another stirrer is used in the female mold. The material is stirred and degassed. On the other hand, when the female mold is not in close contact with the female mold, the space in which the material can flow is wider than when the female mold is in close contact, so the fluidity of the material to be accommodated is higher. As a result, it is possible to perform stirring and degassing with high efficiency by performing stirring and degassing in the female mold.

  Therefore, according to this molding method, it becomes easier to efficiently carry out the stirring and degassing of the material than in the case where the preliminary stirring and degassing step is not present.

  By the way, since the female mold forms the surface of the molded product, defects may occur on the surface of the molded product if the material is not sufficiently impregnated into the female mold.

  On the other hand, according to the molding method of the present invention, the material is stirred in the female mold as well as in the stirring and defoaming step and the preliminary stirring and degassing step preceding it, so that Good impregnation of the entire surface is promoted. As a result, the possibility of defects in the surface properties of the molded article due to insufficient impregnation of the material into the female mold is reduced.

(4) The stirring and defoaming step is
The male mold is mounted on a mold filled with the material by the filling step such that the female mold and the mold are accessible to each other but are separated from each other, thereby assembling the mold unit Process,
Placing the assembled mold unit within the agitator;
Since the female mold and the male mold come close to each other due to the centrifugal force generated by the revolution from the start of the operation of the agitator during the mold closing prevention period, the male mold is prevented from adhering to the female mold. Blocking step,
A prior stirring defoaming step of stirring and degassing the material in the female mold by the stirrer in a state where the male mold is not in close contact with the female mold during the mold closing prevention period;
During operation of the agitator, the female mold and the male mold come close to each other due to the centrifugal force generated by the revolution during the mold lock permission period following the mold lock prevention period, and the male mold is formed into the female mold. Permission process to permit close contact,
A subsequent stirring defoaming step of stirring and defoaming the material in the cavity of the mold unit by the stirrer in a state where the male mold is in close contact with the female mold during the mold closing permission period; The shaping | molding method as described in (1) or (2) term containing.

  According to this molding method, the state in which the material exhibits high fluidity in the female mold in which the male mold is not in close contact during a series of periods in which the molding die unit is subjected to combined motion of rotation and revolution using a stirrer. The stirring and defoaming period coexists with the stirring and defoaming period in which the female mold is in close contact with the mold. In the preceding period, impregnation of the material into the female mold is performed in parallel with the stirring and degassing of the material, and in the subsequent period, the female mold of the material and the molding of the material are performed in parallel with the stirring and defoaming of the material. Impregnation is performed on both male molds.

  Therefore, according to this molding method, the operation of the stirrer for stirring and degassing and impregnating the material does not need to be divided into two operations, and as a result, the efficiency of the molding operation is improved.

(5) In order to carry out the blocking step and the permitting step, the female mold and the male mold are relatively movable in the direction of a common axis and relatively rotatable around the axis. Supported by
In order to perform the blocking step and the permitting step, the mold unit is:
A first member that moves integrally with the male mold;
And a second member that moves integrally with the female mold.
The first member and the second member are rotatable and axially movable relative to each other, and the relative approach limit position in the axial direction between the two members is in close contact with the female mold. The position to be blocked and the position to be permitted vary according to the relative position in the rotational direction between the two,
The relative position in the rotational direction between the first member and the second member is changed by an inertial force acting on the male mold in the rotational direction according to the acceleration or deceleration of the rotation,
The molding method according to (4), wherein the axial relative position between the first member and the second member is changed by an axial centrifugal force acting on the male mold in accordance with the revolution speed.

(6) In order to execute the blocking step and the permission step, the female mold and the male mold are relatively movable in the direction of a common axis, and relatively rotatable around the axis. Supported by
In order to perform the blocking step and the permitting step, the mold unit is:
A first member that moves integrally with the male mold;
And a second member that moves integrally with the female mold.
The first member and the second member are relatively rotatable and axially movable relative to each other, and the approach limit position in the axial direction between the two members prevents the male mold from adhering to the female mold. Change according to the relative position in the rotational direction between
Further, the mold unit is
A movable member axially movable relative to the female mold and rotatable about an axis;
An elastic member that applies an elastic force in a direction opposite to the first axial direction centrifugal force acting on the movable member according to the speed of revolution and away from the female die to the movable member;
An engaging portion that moves integrally with the movable member, which selectively engages at least one of the first member and the second member;
The axial relative position between the movable member and the female mold is changed by an axial resultant force obtained by combining the first axial centrifugal force and the elastic force.
The rotational direction relative position between the movable member and the female mold is generated by the rotational force generated when the axial resultant force is decomposed by the first slope formed on at least one of the second member and the movable member. Change by
The relative position in the rotational direction between the first member and the second member is determined by the second axial centrifugal force acting on the first member and the male mold according to the speed of the revolution; It changes according to the rotational force generated by being decomposed by the second slope formed on at least one of the second member,
The molding method according to (4), wherein the axial relative position between the first member and the second member is changed by the engagement of the engagement portion and the second axial centrifugal force.

(7) A mold unit,
A female mold and a male mold that selectively switch between in a close contact state and in a non close contact state to form a cavity having a predetermined shape, which is relatively movable in the direction of a common axis, and Relatively rotatably supported about an axis,
A first member that moves integrally with the male mold;
And a second member that moves integrally with the female mold.
The first member and the second member are rotatable and axially movable relative to each other, and the relative approach limit position in the axial direction between the two members is in close contact with the female mold. The position to be blocked and the position to be permitted vary according to the relative position in the rotational direction between the two,
The relative position in the rotational direction between the first member and the second member is changed by an inertial force acting on the male mold in the rotational direction according to the acceleration or deceleration of the rotation,
The axial relative position between the first member and the second member is changed by an axial centrifugal force acting on the male mold in accordance with the speed of revolution.
Thereby, a mold unit which is switched between a state in which the male mold is prevented from coming into close contact with the female mold and a state in which the male mold is allowed to adhere to the female mold.

(8) A mold unit,
A female mold and a male mold that selectively switch between in a close contact state and in a non close contact state to form a cavity having a predetermined shape, which is relatively movable in the direction of a common axis, and Relatively rotatably supported about an axis,
A first member that moves integrally with the male mold;
And a second member that moves integrally with the female mold.
The first member and the second member are relatively rotatable and axially movable relative to each other, and the approach limit position in the axial direction between the two members prevents the male mold from adhering to the female mold. Change according to the relative position in the rotational direction between
Further, the mold unit is
A movable member axially movable relative to the female mold and rotatable about an axis;
An elastic member that applies an elastic force in a direction opposite to the first axial direction centrifugal force acting on the movable member according to the speed of revolution and away from the female die to the movable member;
An engaging portion that moves integrally with the movable member, which selectively engages at least one of the first member and the second member;
The axial relative position between the movable member and the female mold is changed by an axial resultant force obtained by combining the first axial centrifugal force and the elastic force.
The rotational direction relative position between the movable member and the female mold is generated by the rotational force generated when the axial resultant force is decomposed by the first slope formed on at least one of the second member and the movable member. Change by
The relative position in the rotational direction between the first member and the second member is determined by the second axial centrifugal force acting on the first member and the male mold according to the speed of the revolution; It changes according to the rotational force generated by being decomposed by the second slope formed on at least one of the second member,
The axial relative position between the first member and the second member is changed by the engagement of the engagement portion and the second axial centrifugal force,
Thereby, a mold unit which is switched between a state in which the male mold is prevented from coming into close contact with the female mold and a state in which the male mold is allowed to adhere to the female mold.

FIG. 1 is a perspective view showing a cap to be molded by a cap molding method according to a first embodiment of the present invention, together with its application. FIG. 2 is a process chart showing the details of the cap forming method and showing the existence of another method performed subsequently to the cap forming method. Fig.3 (a) is a perspective view for demonstrating one part of the cap formation method shown in FIG. 2 in time series, and FIG.3 (b) carries out another part of the cap formation method in time series. It is a perspective view for explaining. FIG. 4 is a cross-sectional view showing the container and the extrusion tool shown in FIG. FIG. 5 is a cross-sectional view showing the stirrer shown in FIG. 6 (a) is a perspective view showing the mold unit shown in FIG. 3 in a mold open state, and FIG. 6 (b) is a perspective view showing the mold unit in a mold closed state. FIG. 7 is a partial sectional view showing the mold unit shown in FIG. Fig.8 (a) is a perspective view for demonstrating sequentially a part of cap formation method shown in FIG. 2, FIG.8 (b) is another part of the cap formation method in time series It is a perspective view for explaining. FIG. 9 is a process chart showing in detail the sealant filling method and the cap mounting method shown in FIG. Fig.10 (a) is a perspective view for demonstrating one part in time of the sealant filling method shown in FIG. 9, and FIG.10 (b) carries out another part of the sealant filling method in time series. FIG. 10 (c) is a perspective view for explaining still another part of the sealant filling method in time series. Fig.11 (a) is a perspective view for demonstrating one part in time of the sealant filling method shown in FIG. 9, and FIG.11 (b) carries out another part of the sealant filling method in time series. It is a perspective view for explaining. Fig.12 (a) is a perspective view for demonstrating in time series a part of cap mounting method shown in FIG. 9, FIG.12 (b) time-sequentially another part of the cap mounting method. It is a perspective view for explaining. FIG. 13 is a graph for conceptually explaining the speed control in the stirrer shown in FIG. FIG. 14 is a perspective view for explaining in chronological order a part of the cap molding method according to the second embodiment of the present invention, which is different from the first embodiment. FIG. 15 (a) is an exploded sectional view showing a mold unit used to carry out a cap molding method according to a third embodiment of the present invention, and FIG. 15 (b) is a mold unit thereof FIG. 6 is a cross-sectional view showing the assembled state. FIG. 16 is a side view for explaining the combined motion of rotation and revolution given to the mold unit shown in FIG. FIG. 17 is a plan view, a cross-sectional view and a partially enlarged view for explaining the principle of relative movement between a female mold and a mold in the mold unit shown in FIG. FIG. 18 is another plan view, a cross-sectional view and a partially enlarged view for explaining the principle of relative movement between a female mold and a mold in the mold unit shown in FIG. FIG. 19 is still another plan view, sectional view and partial enlarged view for explaining the principle of relative movement between a female mold and a mold in the mold unit shown in FIG. FIG. 20 (a) is for explaining an example of the time calendar of the velocity given to the mold unit by a stirrer to realize a series of relative motion between the female mold and the mold shown in FIGS. FIG. 20 (b) is a graph for explaining another example of the time calendar of the speed. FIG. 21 is a flow chart showing the stirring and defoaming step of the cap molding method according to the third embodiment. FIG. 22 (a) is a plan view showing a guide cup and a movable member of a mold unit used to implement a cap molding method according to a fourth embodiment of the present invention, and FIG. 22 (b) is a plan view thereof. FIG. 22 is a side sectional view showing the guide cup and the movable member, and FIG. 22 (c) is a front view showing a second guide groove in the mold unit. FIG. 23 is a partially enlarged front view showing the first guide groove and the engaging portion in the state where the guide pin is positioned at position A in the mold unit shown in FIG. FIG. 24 is a partially enlarged front view showing the first guide groove and the engaging portion in the state where the guide pin is positioned at position B in the mold unit shown in FIG. FIG. 25 is a partially enlarged front view showing the first guide groove and the engaging portion in the state where the guide pin is positioned at position C in the mold unit shown in FIG. FIG. 26 is a partially enlarged front view showing the first guide groove and the engaging portion in the state where the guide pin is located at position D in the mold unit shown in FIG. FIG. 27 (a) is a graph showing an example of a pattern in which the revolution speed of the mold unit shown in FIG. 22 changes with time, and FIG. 27 (b) is a graph showing another example of the pattern. FIG. 28 is a graph showing still another example of the pattern in which the revolution speed of the mold unit shown in FIG. 22 changes with time.

  Hereinafter, some of more specific embodiments of the present invention will be described in detail based on the drawings.

  FIG. 1 is a perspective view showing a cap 10 as a molded article molded by the cap molding method according to the first embodiment of the present invention.

  The cap 10 is made of a synthetic resin and has a shell portion 12 which is generally hollow hemispherical. The shell portions 12 each have a generally hemispherical outer surface and an inner surface, and as a result, a generally hemispherical recess (hollow portion) 14 is formed in the shell portion 12.

  The cap 10 at least partially covers from the outside the fasteners to be fastened to the members to be fastened, thereby preventing the exposure of at least a part of the fasteners. Attached to the fastener.

  In the example shown in FIG. 1, the to-be-fastened member is a panel member 20 made of synthetic resin, and the fastener is a bolt (or a screw, a nut, a rivet) 22 fastened to the panel member 20. It is. In the example shown in FIG. 1, the cap 10 is attached to the bolt 22 in order to cover the portion of the bolt 22 exposed to the outside from the panel member 20 from the outside.

  Furthermore, the cap 10 is substantially airtightly sealed between the cap 22 and the bolt 22 in the mounted state. For the seal, prior to installation, the cap 10 is filled with a sealant, which brings the cap 10 and the bolt 22 into close contact with each other. The close contact prevents foreign matter (gas, liquid, solid) from invading between the cap 10 and the portion of the bolt 22 covered by the cap 10. The adhesion and / or adhesion of the sealant also prevents the cap 10 from coming off the bolt 22 unexpectedly.

  The sealant is made of synthetic resin, and in the present embodiment, is the same material as the cap 10. The reason for this will be described in detail later, but the material commonly used for the sealant and the cap 10 is a high viscosity material, and when it is heated to a certain temperature (for example, 50 ° C.) or more, it cures and cures once Then, it has a thermosetting property in which the property is not restored even if the temperature decreases. In addition, when the material is frozen below a certain temperature (for example, -20 ° C) in the uncured state, the progress (hardening) of the chemical reaction in the material stops. Thereafter, when the material is heated and thawed, the progress (hardening) of the chemical reaction in the material is resumed.

  In the present embodiment, the material commonly used for the sealant and the cap 10 is a two-component mixture type, and is provided by mixing two components: solution A (hardening agent) and solution B (main agent). . An example of solution A is PR-1776 B-2, Part A (promoter and manganese dioxide dispersion) of US PRC-DeSoto International, and an example of solution B combined therewith is US PRC PR-1776 B-2, Part B of DeSoto International (base component, filled modified polysulfide resin).

  A cap forming method according to the present embodiment is shown in a flowchart in FIG. This method is carried out at the production site of the cap 10. Although this method will be described in detail later, for the cap 10 molded by this method, first, the sealant filling method is performed before shipment of the cap 10 (the worker mounts the cap 10 on the bolt 22) Prior to delivery to the site of work), whereby the recess 14 of the cap 10 is filled with the sealant.

  Subsequently, a cap mounting method is carried out at the work site, whereby the cap 10 is mounted on the bolt 22 at the work site by the worker with the cap 10 filled with the sealant.

  Here, the cap forming method according to the present embodiment will be described in detail with reference to FIG.

  As shown in FIG. 2, when this method is carried out at the manufacturing place of the cap 10, first, at step S1, as shown in FIG. Are charged into the container 30 at a ratio of a predetermined ratio (for example, 1:10). In the container 30, the two solutions are mixed, and as a result, the mixture is an example of the molding material of the cap 10 in the present embodiment and an example of the material constituting the sealant.

  The container 30 is shown by FIG. 4 by the longitudinal cross-sectional view. The container 30 has an axially extending hollow case 32 and a bottomed cylindrical chamber 34 coaxially formed in the case 32. The bottom of the chamber 34 has a generally hemispherical recess. The bottom portion having a hemispherical recess allows the material to flow more smoothly in the chamber 34 than if the bottom portion is flat, as a result of which the stirring efficiency of the material is improved.

  At the bottom of the chamber 34, there is formed a discharge passage 36 for discharging the material (a mixture of the liquid A and the liquid B) introduced into the chamber 34 after completion of the stirring and degassing. The passage 36 is selectively closed by a removable plug (not shown). The input of the material into the container 30 is performed in a state where the discharge passage 36 is closed by the plug.

  As shown in FIG. 2, next, in step S2, as shown in FIG. 3A, the container 30 containing the material is given a planetary motion (combined motion of rotation and revolution), whereby The material is defoamed while being stirred (kneaded). In the present embodiment, the rotation axis of the container 30 is inclined with respect to the revolution axis.

  A stirrer 40 is used to perform stirring and degassing according to step S2. The stirrer 40 defoams while stirring the material by applying centrifugal force to the material under vacuum pressure. The stirring and degassing is similarly performed at a predetermined temperature (for example, about 20 to about 30 ° C.) and a predetermined humidity (for example, 50% RH) in the subsequent steps. In this step S2, the pressure in the container 30 is set to a relatively low (closer to atmospheric pressure) vacuum pressure (for example, 40 kPa).

  An example of the stirrer 40 is shown in FIG. 5 in a partial cross-sectional side view.

  The stirrer 40 is a bottomed hollow (for example, hollow cylindrical) housing 42 and a lid (not shown) detachably attached to the open end of the housing 42, and the open end is substantially airtight. And those that are occluded. In the housing 42, a base frame 44 resiliently suspended on the housing 42 is disposed in an anti-vibration state.

  The motor 50 is attached to the base frame 44. A hollow cylindrical rotating frame 54 is connected to the motor 50. The rotating frame 54 is rotated by the motor 50 around the revolution axis.

  A rotation axis is set in the rotation frame 54 at a position eccentric to the revolution axis and in a posture (for example, 45 degrees) inclined to the revolution axis. The rotation axis integrally rotates with the rotating frame 54.

  A container holder 56 is mounted on the rotation frame 54 coaxially with the rotation axis and rotatable around the rotation axis. The container holder 56 is used to hold the above-mentioned container 30 or a mold unit described later. The container holder 56 is rotated by the motor 50 around the rotation axis.

  In the present embodiment, the motor 50 is directly connected to the rotating frame 54, whereas the motor 50 is connected to the container holder 56 by a force transmission system (for example, a belt drive system, a chain drive system, a gear drive system) 60. It is indirectly linked via

  In the example shown in FIG. 5, the force transmission system 60 includes a first rotation shaft 62 rotated by the motor 50 and a first pulley coaxially fixed to the first rotation shaft 62 (a pulley is an example of a rotating body). And a second rotation shaft 66. The second rotation shaft 66 is rotatably attached to the base frame 44 at a position eccentrically parallel to the first rotation shaft 62.

  The force transmission system 60 further includes a second pulley 68 and a third pulley 70 coaxially fixed to the second rotation shaft 66, and a rotating body 74. The rotary body 74 is mounted coaxially with the first rotation shaft 62 relative to the first rotation shaft 62 via a bearing 72. A first belt (a belt is an example of an endless transmission body) 76 is wound around the first pulley 64 and the second pulley 68. A fourth pulley 80 and a fifth pulley 82 are integrally formed on the rotating body 74. A second belt 84 is wound around the third pulley 70 and the fourth pulley 80.

  The force transmission system 60 further includes a third rotation shaft 86 disposed at a position eccentrically parallel to the revolution axis. The third rotation shaft 86 revolves integrally with the rotation frame 54, and rotates relative to the rotation frame 54 via the bearing 87. The force transmission system 60 further includes a sixth pulley 88 and a seventh pulley 89 coaxially fixed to the third rotation shaft 86, and a third belt 90 wound around the fifth pulley 82 and the sixth pulley 88. And have.

  The force transmission system 60 further includes an eighth pulley 91 coaxially and integrally rotating with the container holder 56, a fourth belt 92 wound around the eighth pulley 91 and the seventh pulley 89, and a fourth belt 92 A pair of (in plan view) guide pulleys 93 for guiding the pair of (in plan view) straight portions of the four belts 92 are provided.

  In the present embodiment, the revolution and rotation of the container holder 56 are realized by the motor 50 common to them, and the revolution and rotation of the container holder 56 are mutually dependent on motion. Moreover, in the present embodiment, the ratio between the revolution speed and the rotation speed of the container holder 56 is fixed.

  On the other hand, in one modification of the stirrer 40, the ratio between the revolution speed and the rotation speed is achieved by using the clutch or the CVT while the revolution and the rotation of the container holder 56 are realized by the common motor 50. Is variable. In another variant, the revolution and rotation of the container holder 56 are respectively realized by different motors, whereby the revolution and rotation speeds of the container holder 56 are independent of each other without being dependent on each other. Can be set.

  As shown in FIG. 5, the stirrer 40 further includes a brake 94, an operation panel 95 and a controller 96.

  The brake 94 is provided to reduce at least the rotation speed of the container holder 56 and the rotation speed of the container holder 56 with a steep gradient. In the present embodiment, the brake 94 adopts a system in which an external force is forcibly applied by friction to a movable part (for example, the rotating frame 54) that rotates or linearly moves with the container holder 56, but the present invention is not limited thereto.

  In one example of the brake 94, as shown in FIG. 5, at least one of the annular band 94a mounted on the outer peripheral surface of the rotating frame 54 and the housing 42 facing the band 94a (shown in FIG. In the example, the movable pad 94b is fixed at two positions facing each other in one diameter direction.

  The brake 94 further displaces the movable pad 94b between a retracted position shown in the drawing, which is retracted from the band 94a in the radial direction, and a working position which generates a frictional force between the band 94a and the band 94a. And a displacement mechanism 94c. The displacement mechanism 94c can be manual or automatic. When the displacement mechanism 94c is automatic, it is connected to the controller 96, and the controller 96 electrically controls an actuator (not shown) in the displacement mechanism 94c.

  In the present embodiment, when the rotating frame 54 is decelerated by the brake 94, the motor 50 is decelerated accordingly. As the motor 50 decelerates, the container holder 56 decelerates. Therefore, the deceleration in the direction of rotation of the container holder 56 and the deceleration in the direction of revolution are performed together by the brake 94.

  The operation panel 95 is operated by the user for starting / stopping the stirrer 40 and setting the rotation / revolution speed control pattern.

  The controller 96 is electrically connected to the operation panel 95 and the motor 50. The controller 96 is mainly configured of a computer 97, and as is well known, the computer 97 has a processor 97a and a storage 97b.

  The controller 96 responds to the user's start command to start causing the processor 97a to execute a program (not shown) stored in advance in the storage 97b. Thereby, the motor 50 is controlled such that the rotation / revolution speed control pattern (for example, the pattern represented by the graph in FIG. 13) set by the user is realized.

  Specifically, the controller 96 shifts and drives the motor 50 with an inverter (not shown) that performs variable voltage / variable frequency control according to the setting of the user. In the inverter control, the motor 50 is controlled in an acceleration mode (for example, including a rapid acceleration mode, a slow acceleration mode, etc.), a constant speed mode and a deceleration mode, whereby the rotation of the container holder 56 is achieved. The speed and revolution speeds will each have the desired acceleration slope and the desired deceleration slope.

  In the example shown in FIG. 13, the rotation speed and revolution speed of the container holder 56 are changed with time so that the size is different but the speed change pattern is common to each other, but according to different speed change patterns. It may change with time.

  As shown in FIG. 3A, the container 30 containing the material is contained in the container holder 56 of the stirrer 40, and then the stirrer 40 is operated. During operation, the interior of the housing 42 of the agitator 40 is placed under vacuum pressure. A vacuum pump (not shown) is connected to the stirrer 40, and the air in the housing 42 is drawn by the vacuum pump. Since the space in the container holder 56 and the space in the housing 42 communicate with each other, the air in the container holder 56 is also sucked by the vacuum pump.

  The material is agitated by the centrifugal force caused by the planetary motion by the agitator 40. Furthermore, air bubbles mixed in the material are discharged from the material by the cooperation of the centrifugal force caused by the planetary motion by the stirrer 40 and the negative pressure caused by the vacuum atmosphere, and as a result, the material is defoamed. .

  When the stirring and degassing of the material is completed, the container 30 is taken out of the stirrer 40, as shown in FIG. 3 (a).

  Next, as shown in FIG. 2, in step S3, the material is charged into the syringe 98 (small container for dispensing the material little by little). In this step S3, specifically, as shown in FIG. 3 (b), the material is discharged from the container 30 for one use only, and the discharged single use material is a syringe. It is thrown into 98. All of the material contained in the same container 30 is eventually distributed to a plurality of syringes 98.

  The syringe 98 has a hollow cylindrical shape as shown in FIG. 3B, and a proximal end having a small diameter opening (e.g., a tapered shape) and a large diameter opening. Have a department. The distal end is a small diameter end whereas the proximal end is a large diameter end. The syringe 98 is generally used such that after the material is contained in the syringe 98, the material is expelled from the tip of the syringe 98, for example, positively or by gravity. Ru.

  In the present embodiment, as shown in FIG. 3 (b), an extrusion tool 98 a is pushed into the chamber 34 of the container 30 in order to discharge the material from the container 30. The pusher 98a has an outer surface shape (e.g., a shape having a generally hemispherical convex portion) that complements the inner surface shape of the chamber 34 of the container 30. As the pusher 98a approaches the discharge passage 36 in the chamber 34, material is pushed out of the discharge passage 36.

  In the present embodiment, when the material is transferred from the container 30 to the syringe 98, as shown in FIG. 3 (b), the chamber 30 faces upward while the discharge passage 36 faces downward, as shown in FIG. It is held in. In this state, the pusher 98a is lowered in the chamber 34. As a result, material is pushed downward from the chamber 34.

  Furthermore, in the present embodiment, when the material is transferred from the container 30 to the syringe 98, the syringe 98 is held in the space with the proximal end facing upward and the distal end facing downward. In this state, the material pushed downward from the container 30 is injected from the proximal end of the syringe 98.

  The material then displaces the air inside the syringe 98 and expels the air from the opening at the distal end of the syringe 98 (which is smaller in diameter than the opening at the proximal end, which tends to impede the discharge of air) While the syringe 98 is lowered. As a result, the material is gradually contained within the syringe 98 such that the top surface of the material rises from its tip to its proximal end.

  In the present embodiment, step S3 is performed under the atmospheric pressure, but if it is performed under the vacuum pressure, it becomes possible to more reliably prevent the mixture of air bubbles in the material during the charging to the syringe 98. .

  Subsequently, as shown in FIG. 2, in step S <b> 4, the material is charged into the cavity 110 of the mold unit 100.

  FIG. 6 shows an example of the mold unit 100 in a perspective view. The mold unit 100 has a female mold 102 and a mold 104 which can be relatively approached and separated. In the present embodiment, the female mold 102 functions as a fixed mold having a cavity 110 (here, the space in the female mold 102 exactly), while the male mold 104 is an accurate example of the cavity 110 (here, accurate) Function as a movable mold having a convex portion inserted in the space in the female mold 102). The female mold 102 provides the outer surface of the cap 10 with a desired shape, while the male mold 104 provides the inner surface of the cap 10 with a desired shape.

  Also in the female mold 102 and the male mold 104, the material is a synthetic resin, and the synthetic resin is, for example, a synthetic resin having self-lubricity, and such a synthetic resin is, for example, PTFE (Teflon (registered trademark)) It is.

  The female mold 102 and the male mold 104 have a central line common to them, and the male mold 104 is linearly movable with respect to the female mold 102 along the central line. In this embodiment, in order to enable the linear movement, a plurality of metal guide rods 112 parallel to each other are detachably fixed to the female die 102. Corresponding to this, the male mold 104 is formed with a plurality of through holes in which the guide rods 112 are slidably fitted.

  In FIG. 6A, the male mold 104 is retracted from the female mold 102, and the material can be introduced into the cavity 110 of the female mold 102 (here, precisely the space in the female mold 102). 6B shows that the male mold 104 is in close contact with the female mold 102, and the space formed between the male mold 104 and the female mold 102 is the same as that of the cap 10. The state (mold closing state) which defines a shape is shown.

  FIG. 7 is a side view showing the mold unit 100 in a mold closed state. The mold unit 100 comprises a hollow cylindrical case 114 which secures the female mold 102 at its bottom. The case 114 is fitted to the container holder 56 of the stirrer 40 without wasteful gap, and has a shape that can be accommodated in the container holder 56 without loose during the operation of the stirrer 40.

  In step S4 shown in FIG. 2, as shown in FIG. 8A, the material is pushed out of the syringe 98, whereby the cavity 110 of the female die 102 (here, precisely, the space in the female die 102). The material is put into).

  Further, in this step S4, as shown in FIG. 8A, the female mold 102 (the state in which the guide rod 112 is removed) is accommodated in the container holder 56 of the agitator 40 together with the case 114. In this state, the stirrer 40 is operated with the female mold 102 under vacuum pressure. As a result, the material introduced into the cavity 110 of the female mold 102 (here, precisely the space in the female mold 102) is agitated and defoamed. At this time, flattening (surface leveling) of the surface of the material filled in the cavity 110 (here, precisely, the space in the female mold 102) is also performed. Thereafter, as shown in FIG. 8A, the female mold 102 is taken out of the stirrer 40.

  In this step S4, the pressure in the container holder 56 is set to a higher vacuum pressure (for example, 20 kPa) than in the case of the above-mentioned step S2.

  By the way, the higher the vacuum pressure of the material, the higher the degassing effect of the material. Also, the greater the amount of material, the higher the flowability of the material, and thus the material is more likely to generate heat due to friction during stirring by centrifugal force. On the other hand, the higher the temperature of the material, the easier it is to foam. Moreover, in the environment which is easy to foam, the higher the vacuum pressure, the more the foaming is promoted.

  On the other hand, the material in the container 30, which is the target of stirring and degassing in step S2, is more likely to generate heat because it is larger in amount than the material in the female mold 102 which is the target of stirring and degassing in step S4. It is easy to foam.

  Thus, in the present embodiment, the stirring and degassing in step S2 is performed under a lower vacuum pressure than the stirring and degassing in step S4. For the same reason, the stirring and degassing in step S5 is performed under a higher vacuum pressure than the stirring and degassing in step S2, and the stirring and degassing in step S5 has the same height as the stirring and degassing in step S4. Under the vacuum pressure of

  Subsequently, in step S5 shown in FIG. 2, the cap 10 is manufactured by rotational molding using the mold unit 100.

  Specifically, as shown in FIG. 8 (b), the guide rod 112 and the mold 104 are attached to the mold 102 filled with the material that has been stirred and defoamed, and the case 114 is attached to them. . Thus, the mold unit 100 is assembled. Thereafter, the entire mold unit 100 is accommodated in the container holder 56 of the stirrer 40 in the mold open state. Thereafter, the stirrer 40 is activated.

  At the start of the operation of the stirrer 40, the male mold 104 is not in close contact with the female mold 102, and the fluidity of the material in the female mold 102 is not substantially inhibited by the male mold 104. During this period (the period in which the male mold 104 does not adhere to the female mold 102), the material is efficiently stirred and defoamed. The stirring and degassing is also carried out under relatively high vacuum pressure (as mentioned above, for example, 20 kPa).

  The centrifugal force acting on the male mold 104 by the planetary motion increases as the rotation speed and / or revolution speed of the stirrer 40 rises up to the target value, and accordingly, the male mold 104 acts on the guide rod 112. The impetus for approaching female die 102 also increases.

  Eventually, when the driving force reaches a point at which the male mold 104 overcomes the frictional resistance with the guide rod 112, the male mold 104 moves along the guide rod 112 in a direction approaching the female mold 102. Eventually, the male mold 104 adheres to the female mold 102. After the close contact, the stirrer 40 continues to operate, whereby the material in the mold unit 100 is stirred and defoamed even in the mold closed state. The stirring and degassing is also carried out under relatively high vacuum pressure (as mentioned above, for example, 20 kPa).

  In the present embodiment, in order to improve the flowability of the material in the cavity 110 as much as possible at the beginning of molding, thereby maximizing the effect of stirring and defoaming, the male mold 104 is used at the beginning of molding. The close contact with the female mold 102 is prevented. Only after a certain time has elapsed, the male mold 104 is allowed to adhere to the female mold 102.

  When rotational molding by the mold unit 100 is completed, the entire mold unit 100 is taken out of the stirrer 40. At this time, the mold unit 100 is in a mold closed state as shown in FIG. 8 (b).

  Thereafter, in step S6 shown in FIG. 2, clamping of the mold unit 100 is performed. Specifically, the female mold 102 and the female mold 104 are firmly clamped using a clamp jig (not shown). This is to ensure that the female mold 102 and the female mold 104 will be separated from each other unexpectedly in a subsequent heat curing step.

  Subsequently, heat curing is performed in step S7 shown in FIG. Specifically, the entire mold unit 100 is placed in a high temperature chamber (eg, about 40 to about 60 ° C.), which causes the material in the cavity 110 of the mold unit 100 to be heat set.

  Thereafter, in step S8 shown in FIG. 2, the male mold 104 is retracted from the female mold 102 in order to take out the cap 10 as a finished product from the mold unit 100. A disintegration takes place.

  Subsequently, in step S9 shown in FIG. 2, the cap 10 is subjected to finish processing such as deburring. Thus, the manufacture of the cap 10 is completed.

  In addition, in the present embodiment, as shown in FIG. 8A, in step S4, the mold 102 filled with the material is made to move in a planetary motion by the stirrer 40, whereby the inside of the female mold 102 is moved. The material is stirred and defoamed, and then, in step S5, the mold unit 100 filled with the material is planetaryly moved by the stirrer 40, whereby the material in the mold unit 100 is stirred and defoamed, etc. Stirring and degassing using the stirrer 40 is performed twice.

  On the other hand, it is possible to practice the present invention in a mode in which implementation of step S5 is omitted, that is, as soon as implementation of step S4 is completed, steps S6 and S7 are implemented. If only the stirring and degassing in step S4 is performed on the same material in the female mold 102, a sufficient stirring and degassing effect may be realized.

  Thereafter, as shown in FIG. 2, the sealant filling method is performed.

  As shown in FIG. 9, when the sealant filling method is performed, first, in step S11, as shown in FIG. 10A, the cap 10 as a finished product is loaded into the cavity 110 of the female mold 102. Thus, in preparation for the filling of the sealant from above, the cap 10 is held with the opening of the recess 14 in the upward position.

  It is not essential to use the female mold 102 to hold the cap 10, although other dedicated jigs may be used, but if the female mold 102 is used, it may be dedicated to hold the cap 10 You do not have to dare to make a jig.

  Thereafter, as shown in FIG. 10A, the liquid sealant 118 is filled in the recess 14 of the cap 10 which is held in the posture. The sealant 118 is a material extruded from the syringe 98, which fills the recess 14. In the present embodiment, as described above, the material constituting the cap 10 and the sealant 118 filled in the recess 14 of the cap 10 have the same composition.

  Next, in step S12 shown in FIG. 9, stirring and degassing of the sealant 118 is performed using the stirrer 40. Specifically, as shown in FIG. 10B, the mold 102 filled with the sealant 118 is accommodated in the container holder 56 of the stirrer 40, and in this state, the container holder 56 of the stirrer 40 is vacuumed. It is operated in a certain state (for example, the same vacuum pressure as steps S4 and S5). Thereby, the sealant 118 filled in the recess 14 of the cap 10 is stirred and degassed. At this time, flattening (surface leveling) of the surface of the sealant 118 filled in the recess 14 is also performed. Thereafter, as shown in FIG. 10 (b), the female mold 102 is taken out of the stirrer 40.

  Subsequently, the sealant 118 is frozen together with the cap 10 in step S13 shown in FIG. Specifically, as shown in FIG. 10C, the female mold 102 holding the cap 10 is inserted into the freezer 120 with the case 112 and the cap 10 filled with the sealant 118. Ru. The internal temperature of the freezer 120 is, for example, about -50 to about -70.degree. Moreover, freezing time is 1 hour, for example. When the sealant 118 freezes (solidifies, solidifies), the female mold 102 is removed from the freezer 120.

  Thereafter, in step S14 shown in FIG. 9, a plurality of product kits 124 are manufactured. Specifically, as shown in FIG. 11 (a), the cap 10 filled with the frozen sealant 118 is removed from the female mold 102, and a plurality of caps 10 removed in this way are frozen. The one filled with the sealant 118 is inserted into a plurality of recesses on the pallet 122. Thereby, a plurality of caps 10 are aligned on one pallet 122, whereby one product kit 124 is completed.

  Subsequently, in step S15 shown in FIG. 9, the product kit 124 is cooled as a whole. Specifically, as shown in FIG. 11 (b), a low temperature chamber (not shown, for example, a constant temperature chamber of about −50 to about −70 ° C. not shown) in which the product kit 124 is located at the manufacturing place of the cap 10. (Including a box), thereby preventing the sealant 118 in the cap 10 from thawing unexpectedly during storage.

  Thereafter, in step S16 shown in FIG. 9, the cap 10 filled with the sealant 118 is shipped to the work site in a cold storage state. This completes the sealant filling method.

  As a result, the manufacture of the cap 10 as a final product is finished. The cap 10 is a combination of the cap 10 itself as an intermediate finished product and a frozen sealant 118 filling the cap 10.

  That is, at this time, the cap 10 as a final finished product is a solid outer layer (shell portion 12) formed of a material whose fluidity can not be restored even if it is thawed since curing is already completed. And a solid inner layer formed of a material (sealant 118) that is located inside the outer layer and that can restore its flowability if thawed since it has not yet been cured It is composed.

  When the sealant filling method is completed as described above, then, as shown in FIG. 9, the cap attachment method is started at the work site, not at the manufacturing site.

  Specifically, first, at step S21, the product kit 124 is received at the work site. Next, in step S22, the received product kit 124 is cooled in a freezer (not shown).

  Subsequently, in step S23, when it is necessary to start the cap mounting operation using the product kit 124, the product kit 124 is taken out of the freezer, and then, as shown in FIG. 12 (a), It is thawed at a thaw place (not shown, for example, thaw chamber). The thawing can be performed, for example, at normal temperature, directly heated by a heater (for example, a hot air heater having a drying function), or indirectly heated by water bathing.

  When the cap 10 is thawed, the shell portion 12 remains solid and does not liquefy, but the sealant 118 liquefy to become fluid again.

  Thereafter, in step S24 (or in parallel with the thawing in step S23), the product kit 124 is dried by a dryer (not shown), thereby removing condensation generated on the surface of the cap 10 by thawing. The dryer can blow off the moisture adhering to the surface of the cap 10, for example, by blowing air or warm air at normal temperature.

  Subsequently, in step S25, the required product kit 124 is taken out from the thawing place or the drying place, and the taken out product kit 124 is, as shown in FIG. Transported to Thereafter, in step S26, as shown in FIG. 12 (b), the operator takes out the cap 10 filled with the sealant 118 from the pallet 122 to be used from now, and the cap 10 is a panel member of the bolt 22. Attach to the part exposed from 20.

  At this time, while the cap 10 is solid, the sealant 118 in the cap 10 exhibits fluidity, whereby the cap 10 is attached to the bolt 22. The sealant 118 includes the cap 10 and the bolt 22. It deforms relatively freely so as to fill the gap between the two with no leakage. As a result, a seal between cap 10 and bolt 22 is achieved. This is the end of the cap mounting method.

  As is apparent from the above description, in the present embodiment, in the first half of step S4 shown in FIG. 2, a portion for pushing the material from the syringe 98 and filling the female die 102 with the material is In the second half of step S4 shown in the figure, which constitutes an example of the "filling step" in the above item (1), the mold 102 which is filled with the material is rotated and revolved by the stirrer 40. The portion for the step S5 shown in the same figure and the step S5 shown in the same figure constitute an example of the "stirring and defoaming step" in the same paragraph, and the step S7 shown in the same An example is constructed.

  Furthermore, in the present embodiment, the portion in the second half of step S4 shown in FIG. 2 for rotating and revolving the mold 102 filled with the material by the stirrer 40 is the section in the above (3). An example of the "pre-stirring defoaming step" and the first half of step S5 shown in the same figure, and a portion for assembling the mold unit 100 is an example of the "assembly step" in the same section. In the second half of step S5 shown in the same figure, a portion for rotating and revolving the assembled mold unit 100 by the stirrer 40 is the “main stirring defoaming step in the same section”. Constitute an example of

  Next, a cap molding method according to a second embodiment of the present invention will be described. However, the present embodiment differs from the first embodiment only in the contents of step S3 shown in FIG. 2 and the other steps are common, so only different elements will be described in detail, and common elements will be described. Duplicate descriptions will be omitted.

  In the first embodiment, as shown in FIG. 3 (b), when the material is transferred from the container 30 to the syringe 98, the container 30 faces the chamber 34 upward and the discharge passage 36 downward. It is held in space. In this state, the pusher 98a is lowered in the chamber 34. As a result, material is pushed downward from the chamber 34.

  Furthermore, in the first embodiment, when the material is transferred from the container 30 to the syringe 98, the syringe 98 is held in the space with the proximal end facing upward and the distal end facing downward. In this state, the material pushed downward from the container 30 is injected from the proximal end of the syringe 98.

  On the other hand, in the present embodiment, as shown in FIG. 14, when the material is transferred from the container 30 to the syringe 98, first, while the container 30 faces the chamber 34 as in the first embodiment, And the discharge passage 36 is held in the space with the posture facing downward. In this state, the opening of the chamber 34 is closed by the pushing device 98a. Thereby, even if the container 30 is turned upside down, the material from the container 30 is prevented from leaking from the opening of the chamber 34 by gravity.

  The container 30 is then inverted from the initial position so that the container 30 is held in space with the discharge passage 36 facing up and the chamber 34 facing down. Subsequently, the syringe 98 is held in the space such that the proximal end faces upward and the distal end faces downward and the distal end and the outlet of the discharge passage 36 coincide with each other. Ru.

  In this state, the pusher 98a is raised in the chamber 34. As a result, material is pushed upward from the chamber 34. Material pushed upwardly out of the container 30 is injected from the distal end of the syringe 98 rather than the proximal end.

  The material then displaces the air inside the syringe 98 and expels the air from the opening at the proximal end of the syringe 98 (which is larger in diameter than the opening at the distal end, so it is difficult to inhibit the discharge of air) While rising up the inside of the syringe 98. As a result, the material is gradually contained within the syringe 98 such that the top surface of the material rises from its tip to its proximal end.

  Thus, in the present embodiment, when the material is injected into the syringe 98, it is injected from the distal end of the syringe 98, so the air in the syringe 98 is compressed more than when injected from the proximal end. It is not necessary. As a result, when the material is injected into the syringe 98, the possibility that the material is mixed with air in the syringe 98 is reduced as compared to the case where the material is injected from the proximal end of the syringe 98.

  Next, a cap molding method according to a third embodiment of the present invention will be described. However, this embodiment is different from the first embodiment in the main part of the molding method, the structure of the mold unit, and the speed control of the stirrer, and the other elements are common, so only the different elements are different. Detailed description will be made, and redundant description of common elements will be omitted.

  In the first embodiment, as shown in FIG. 2 and FIG. 8, only the mold 102 filled with the material is rotated and revolved by the stirrer 40 in step S4 before assembling the mold unit 100, and thereafter In step S5, the mold unit 100 is assembled, and the assembled mold unit 100 is rotated and revolved by the stirrer 40.

  On the other hand, in the present embodiment, the implementation of step S4 is omitted, and instead, step S5 has a mold closing prevention period in the first half thereof and a mold closing permission period in the second half thereof. That is, in the present embodiment, the stirring and degassing step, which will be described in detail later with reference to FIG. 21, is carried out so as to have a mold closing prevention period and a mold closing permission period.

  In the mold closing prevention period, the material is stirred and defoamed in the female mold while preventing the male mold from adhering to the female mold in the assembled mold unit. On the other hand, in the mold closing permission period, the male mold is allowed to adhere to the female mold, and the material is stirred in the narrow cavity formed by the male mold and the female mold adhering to each other after the close contact. Defoamed.

  In FIG. 15, a mold unit 140 used to carry out the above-described stirring and defoaming step is shown in an exploded view and an assembly view, both of which are front views.

  The forming unit 140 includes a female die 142 and a male die 144 each having a cylindrical outer peripheral surface, similar to the forming die unit 100 shown in FIGS. 6 and 7. A cavity 146 is defined by the female mold 142 and the female mold 144. Both the female mold 142 and the male mold 144 are mainly composed of POM (polyacetal), which is an example of an engineering plastic excellent in self-lubricity, and the other of the female mold 142 and the female mold 144 is the other. The portion in contact with the member is made of PTFE (Teflon (registered trademark)).

  The forming unit 140 further includes a guide cup 150 (first tubular member), a spacer 152, and a die fixing cup 154 (a second tubular member larger in diameter than the first tubular member). Have.

  The guide cup 150 has a bottomed cylindrical shape and has a cylindrical portion 156 and a bottom portion 158 closing one end of the cylindrical portion 156. While the female die 142 is fitted to the guide cup 150 so as to contact the bottom portion 158 of the guide cup 150, the female die 142 can be attached to and removed from the inner peripheral surface of the guide cup 150. Are fixed relatively immovably both in the axial direction and in the circumferential direction. An example of the material which constitutes this guide cup 150 is POM.

  The spacer 152 also has a cylindrical shape with a bottom, and the guide cup 150 is slidably fitted on the inner peripheral surface of the spacer 152, and is removable and, in the mounted state, in the axial direction and in the circumferential direction Relative movement is fixed.

  The mold fixing cup 154 also has a cylindrical shape with a bottom, and the spacer 152 is slidably fitted on the inner peripheral surface of the cup, and is removable and in the circumferential direction also in the axial direction in the mounted state Even immobile is fixed.

  The mold fixing cup 154 is fitted without looseness in the container holder 56, and is removable from the inner peripheral surface of the container holder 56, and in the mounted state, it is relatively movable in the axial direction and in the circumferential direction. It is immovably fixed to the container holder 56.

  In addition to the female mold 142, a male mold 144 is also fitted to the inner peripheral surface of the guide cup 150. The female mold 142 is fixed to the guide cup 150, whereby the female mold 142 always rotates and revolves integrally with the guide cup 150. On the other hand, the male mold 144 is movably fitted to the guide cup 150 in the axial direction and in the circumferential direction. As a result, the male mold 144 can be approached and separated in the axial direction relative to the female mold 142 while being guided by the inner peripheral surface of the guide cup 150. However, the relative movement of the male mold 144 with respect to the female mold 142 is restricted by the combination of the guide pin and the guide slot fitted together, which will be described later.

  As shown in FIG. 16, the forming unit 140 is revolved around a revolving axis, and is rotated around a rotation axis inclined with respect to the revolving axis at a position eccentric from the revolving axis.

  As shown in FIGS. 15 and 17, the male die 144 has a plurality of radially extending guide pins 160 mounted thereon. In the example shown in FIGS. 15 and 17, two guide pins 160 are aligned in one diameter direction.

  As shown in FIG. 15, the cylindrical portion 156 of the guide cup 150 is formed with a plurality of guide slots (or guide grooves) 162 extending from the upper end thereof. Each guide pin 160 is engaged with each guide slot 162 so as to be relatively movable along its longitudinal direction. The width dimension of each guide elongated hole 162 is set to be larger than the diameter dimension of each guide pin 160.

  As shown in FIGS. 15 and 17, each of the guide elongated holes 162 extends in the circumferential direction from the end of the first portion 170 which extends in the axial direction (downward) from the upper end of the cylindrical portion 156 A second portion 172, a third portion 174 extending obliquely downward from the end of the second portion 172, and a fourth portion 176 extending axially (downward) from the end of the third portion 174 .

  As described above, the male mold 144 can move relative to the guide cup 150 in both the axial direction and the circumferential direction, but the movement locus of the male mold 144 is a joint movement of the guide pin 160 and the guide elongated hole 162. It is defined by the action. Also, the relative displacement (including relative rotation and relative movement) between the male mold 144 and the guide cup 150 causes relative displacement between the male mold 144 and the female mold 142.

  The relative displacement between the male mold 144 and the guide cup 150 can be roughly described by acting on the inertial force (mainly direction and size) of the male mold 144 in the rotation direction and the male mold 144. It is performed based on the axial component (magnitude) of the centrifugal force.

  When the stirrer 40 is stopped, the guide pin 160 is in an initial state located at the end (lower end position) of the first portion 170, as shown in FIG. 17, due to the gravity acting on the male die 144.

  In FIG. 20A, an example of the time calendar of the speed (at least the rotation speed of the rotation speed and the revolution speed) given to the forming unit 140 by the stirrer 40 is represented by a graph.

  In the example shown in FIG. 20A, the rotational speed (rotational speed) and the revolutional speed (rotational speed) of the mold unit 140 are different from each other in size but the speed change patterns are common to each other. . The rotation direction of the forming unit 140 is constant during the operation of the stirrer 40, and as shown in FIG. 17, in each of the guide long holes 162 formed in the cylindrical portion 156 of the guide cup 150, the first The direction from the portion 170 toward the fourth portion 176 is matched.

  Furthermore, in the example shown in FIG. 20 (a), a series of speed control is performed in the first rapid acceleration period A, the second constant velocity period B, the third rapid deceleration period C, the fourth slow acceleration period D, the fifth rapid acceleration period D. There is an acceleration period E, a sixth constant velocity period F, and a seventh slow deceleration period G.

  In the first rapid acceleration period A, the motor 50 is driven in the rapid acceleration mode, whereby the female die 142 is accelerated in the rotational direction. Accordingly, as shown in FIG. 17, in the male die 144, the direction opposite to the direction in which the second portion 172 extends from the end (lower end position) of the first portion 170 (reverse direction of the rotation direction of the female die 142) Inertial force acts on. As a result, the guide pin 160 is pressed against the side wall of the first portion 170 in the initial position shown in FIG.

  In the second constant velocity period B, the motor 50 is driven in the constant velocity mode, whereby both the female die 142 and the male die 144 are allowed to rotate and revolve at a constant velocity. At this time, the guide pin 160 is held at the initial position shown in FIG. At this point, since the male mold 144 is not yet in intimate contact with the female mold 142, the material in the female mold 142 is efficiently stirred and defoamed under high fluidity despite exhibiting high viscosity. Ru. In the second constant velocity period B, complete impregnation of the material into the female mold 142 is also promoted.

  In the third rapid deceleration period C, the brake 94 is operated in a state where the power supply to the motor 50 is cut off, whereby the female die 142 is decelerated in the rotational direction. Accordingly, as shown in FIG. 18, in the male die 144, the same direction (the same direction as the rotational direction of the female die 142) as the second portion 172 extends from the end (lower end position) of the first portion 170. Inertial force acts. As a result, the guide pin 160 moves from the initial position shown in FIG. 17 toward the end (right end position) of the second portion 172 as shown in FIG. 18, whereby the male mold 144 is moved to the female mold 142. Relatively, it rotates in the circumferential direction relatively.

  When an inertial force in the same direction continuously acts on the male mold 144, the guide pin 160 transitions from the end (right end position) of the second portion 172 shown in FIG. 18 to the third portion 174, to the third portion 174. Move along. The third portion 174 is inclined with respect to the circumferential direction of the male mold 144. Therefore, the male mold 144 moves in the axial direction and gradually approaches the female mold 142. The guide pin 160 eventually reaches the end (right end position) of the third portion 174.

  In the present embodiment, the third portion 174 is inclined downward with respect to the circumferential direction of the male mold 144. Therefore, the possibility that the guide pin 160 reverses the third portion 174 unplannedly against gravity is lessened than when the third portion 174 is not inclined.

  In the fourth slow acceleration period D, with the guide pin 160 positioned at the fourth portion 176, the motor 50 is driven in the slow acceleration mode, whereby the male die 144 is accelerated in the rotational direction. As a result, an axial centrifugal force is generated in the male die 144, and the centrifugal force increases with time. The centrifugal force acts on the mold 144 in a direction (downward) in which the male mold 144 approaches the female mold 142. Thereby, as shown in FIG. 19, the guide pin 160 descends along the fourth portion 176 to approach the female die 142.

  In the fourth slow acceleration period D, the axial centrifugal force acting on the male die 144 increases with a gentle gradient than when the motor 50 is driven in the rapid acceleration mode. Therefore, the speed at which the male mold 144 approaches the female mold 142 is reduced. Therefore, it is prevented that the male mold 144 rushes into the material in the female mold 142 in a state in which air is caught.

  As shown in FIG. 19, when the axial centrifugal force continuously acts on the male mold 144, finally, the stopper 180 installed on the front surface of the male mold 144 is installed on the rear surface of the female mold 142. It abuts on the receiving surface 182, whereby the male die 144 reaches the access limit to the female die 142. As a result, the male mold 144 adheres to the female mold 142.

  In the fifth rapid acceleration period E, the motor 50 is driven in the rapid acceleration mode, whereby the forming die unit 140 rapidly (both in the rotational direction and in the rotational direction) (larger than in the preceding fourth slow acceleration period E Accelerated).

  In the sixth constant velocity period F, the motor 50 is driven in the constant velocity mode, whereby the female die 142 and the male die 144 are integrally rotated and revolved at a constant velocity. As a result, the material in the narrow cavity 146 formed by the female mold 142 and the female mold 144 is deaerated under vacuum pressure while being agitated. In the sixth constant velocity period F, complete impregnation of the material into the male mold 142 and the male mold 144 is also promoted.

  In the seventh slow deceleration period G, the motor 50 is driven in the deceleration mode, whereby the male die 144 and the female die 142 are decelerated integrally in the rotation direction as well as in the revolution direction. In the seventh slow deceleration period G, since the brake 94 is not operated, a speed gradient slower than that in the third rapid deceleration period C is realized. Eventually, the male mold 144 and the female mold 142 stop.

  Here, the stirring and degassing step in the present embodiment will be described in detail by referring to FIG.

  In this stirring and defoaming step, first, in step S31, as shown on the leftmost side in FIG. 8B, the mold 142 filled with the material, the mold 144 filled with the material, the female mold 142 and the mold 144 The assembly process is performed by mounting the mold units 140 so as to be accessible to each other but to be separated from each other.

  Next, in step S32, as shown at the center in FIG. 8B, an arrangement step of arranging the assembled mold unit 140 in the stirrer 40 is performed.

  Subsequently, in step S33, the mold unit 140 is moved close to the female mold 142 by the centrifugal force generated by revolution from the start of the operation of the stirrer 40 to the female mold 142 during the mold blocking period. A blocking step is performed to block adhesion to the female mold 142. In the present embodiment, as shown in FIG. 20A, the mold clamping prevention period includes the first rapid acceleration period A, the second constant velocity period B, and the third rapid deceleration period C. Be done.

  In parallel with step S33, in step S34, the stirring and defoaming material is stirred and defoamed in the female die 142 by the stirrer 40 in a state where the female die 142 is not in close contact with the female die 142 during the mold closing prevention period. A degassing step is performed.

  Subsequently, in step S35, during operation of the stirrer 40 and in a mold closing permission period following the mold closing prevention period, the mold 144 approaches the mold 142 by the centrifugal force acting on the mold 144 and the mold 144 is molded. A permission process is performed to permit close contact with the female mold 142. In the present embodiment, as shown in FIG. 20A, the mold closing permission period is the fourth slow acceleration period D, the fifth rapid acceleration period E, the sixth constant velocity period F, and the seventh slow deceleration. It is configured to include the period G.

  In parallel with step S35, in step S36, the stirrer 40 stirs the material in the cavity 146 of the mold unit 140 while the mold 144 is in close contact with the female mold 142 during the mold closing permission period. A subsequent stirred degassing step is performed to degas.

  In the first embodiment, as shown in FIGS. 8A and 8B, the entire mold unit 100 in which the cavity 110 is filled with material is provided with rotation and revolution by the stirrer 40 to stir and defoam the material. A step of giving rotation and revolution only to the female mold 102 filled with the material by the stirrer 40 and stirring and defoaming the material (ie, step S4 in FIG. 2) prior to the step (ie, step S5 in FIG. 2) Is done. The stirring and degassing of the material in the female mold 102 is performed in two steps using the stirrer 40.

  This is because stirring and degassing in step S5 is performed in a state where the material is restrained in the narrow cavity 110 and the fluidity is low, so the step S4 precedes step S4, and the material is restrained in the female die 102. It is carried out to stir and degas the material in a highly fluid state.

  On the other hand, in the present embodiment, while the step S4 is omitted, the step S5 is performed in a state where the mold 144 is not attached to the female die 142, and the defoaming with stirring in the female die 142 and the die 144 for female die 142. The subsequent stirring and degassing with H 2 is mounted is carried out during continuous operation of the stirrer 40.

  Therefore, according to the present embodiment, stirring and degassing of the material in the female die 142 can be performed without stopping the operation of the stirrer 40, whereby the working efficiency of the stirring and degassing is improved, and the cap 10 is formed. The time required for the production of the cap 10 is reduced, and the production efficiency of the cap 10 is improved.

  FIG. 20B is a graph showing a modification of the speed calendar in the example shown in FIG. 20A (hereinafter referred to as the “first example”).

  The time calendar of speed in the example shown in FIG. 20B (hereinafter referred to as “second example”) is common to the basic speed change pattern with respect to the time calendar of speed in the first example.

  Specifically, in the second example, the motor 50 is driven in the rapid acceleration mode during the first rapid acceleration period A, and during the second constant velocity period B and the sixth constant velocity period F. In each case, the motor 50 is driven in the constant speed mode, and during the seventh slow deceleration period G, the motor 50 is driven in the deceleration mode.

  However, in the second example, as a period corresponding to the third rapid deceleration period C in the first example, the deceleration period C1 for driving the motor 50 in the deceleration mode without operating the brake 94 and the brake 94 are activated. A combination with a deceleration period C2 is adopted.

  In this second example, unlike the first example, first, during the deceleration period C1, the current control of the motor 50 causes the rotational speed and the revolution speed to be sufficiently close to zero without depending on the brake 94. After being decelerated, the brake 94 is actuated during the deceleration period C2, whereby an inertial force is applied in the direction of rotation of the male mold 144. According to the second example, the load on the brake 94 and the motor 50 is reduced because the speed of the rotating frame 54 when the actuation of the brake 94 is started is lower than in the first example.

  Also, in this second example, three constant speed periods D1, D2 and D3 and three rapid accelerations are used as a period corresponding to the combination of the fourth slow acceleration period D and the fifth rapid acceleration period E in the first example. The alternating periods E1, E2 and E3 are employed. During the constant speed periods D1, D2 and D3, the motor 50 is driven in the constant speed mode, and during the rapid acceleration periods E1, E2 and E3, the motor 50 is driven in the rapid acceleration mode. Be done.

  In this second example, by alternately selecting the constant speed mode and the rapid acceleration mode, it is possible to generate a smaller centrifugal force in the mold 144 than in the case where the rapid acceleration mode is continuously selected. Therefore, as the male mold 144 tries to approach the female mold 142 by the centrifugal force acting on the male mold 144, the guide pin 160 descends along the fourth portion 176 as shown in FIG. Speed is slowed down. Therefore, also in the second example, as in the first example, the male mold 144 is prevented from rushing into the material in the female mold 142 in a state in which air is caught.

  In addition, in the present embodiment, the inertia necessary to move the guide pin 160 from the lock position that prevents the male die 144 from approaching the female die 142 to the unlock position that permits the approach. A force is generated by actuation of the brake 94. On the other hand, when the necessary inertial force can be realized by current control of the motor 50, it is not necessary to use the brake 94.

  Next, a cap molding method according to a fourth embodiment of the present invention will be described. However, this embodiment differs from the third embodiment in the structure of the mold unit and the speed control of the stirrer, and the other elements are the same, so only the different elements will be described in detail and common. Duplicate descriptions of elements will be omitted.

  In the third embodiment, as described above, the mold unit 140 moves with the male die 144 with the guide pin 160 (an example of the “first member” in the item (5)) and the female die 142. And a guide elongated hole 162 (an example of the "second member" in the item (5)). The guide pin 160 acts on the male mold 144 in the direction of rotation due to rotation, and at least the directionally changes with time the inertial force that changes with time, and the magnitude that acts on the male mold 144 due to revolution changes in size with time The combination with the axial centrifugal force causes relative movement along the guide slot 162 having a predetermined path. As a result, switching is made between a state in which the male mold 144 is prevented from coming into close contact with the female mold 142 and a state in which the male mold 144 is allowed to be in intimate contact.

  As described above, in the third embodiment, relative movement between the guide pin 160 and the guide long hole 162 is performed without interposing another movable member, as a result, the number of parts can be easily reduced. obtain.

  On the other hand, in the present embodiment, relative movement between the guide pin 160 and the guide groove is performed by interposing another movable member in order to improve its stability and design ease. Further, in the present embodiment, the speed control of the stirrer 40 is performed by the current control of the motor 50 without using the brake 94.

  FIG. 22 (a) is a plan view showing a mold unit 200 for carrying out the cap molding method according to the present embodiment. However, since this mold unit 200 is a mold unit 140 according to the third embodiment and has a basic configuration in common with that shown in FIG. 17, duplicate descriptions will be omitted. The mold unit 140 has a guide cup 150 and a spacer 152 as shown in FIG. 17, but the mold unit 200 according to the present embodiment has a guide cup 210 and a movable member 212 instead of them.

  In FIG. 22 (a), only the assembly of the guide cup 210 and the movable member 212 in the mold unit 200 is shown in plan view, and in FIG. 22 (b), the assembly is a side sectional view. It is shown.

  As shown in FIG. 22 (b), the guide cup 210 has a generally circular plate-shaped bottom portion 222, and a lower flange 224 protrudes radially outward from the bottom portion 222. The guide cup 210 further comprises a cylindrical portion 226 which extends coaxially to the bottom 222 and perpendicularly from the bottom 222. The cylindrical portion 226 is formed with a through hole 227 as an air circulation hole. The bottom 222 is formed with a through hole 228 as an air circulation hole. At the outer peripheral edge of the lower flange 224, notches 230 penetrating the lower flange 224 in the thickness direction are formed as air circulation holes at a plurality of locations separated in the circumferential direction, respectively. An example of the material which constitutes this guide cup 210 is POM.

  The outer peripheral surface of the female die 142 is fitted to the inner peripheral surface of the cylindrical portion 226 in the same manner as shown in FIG. The female mold 142 is fixed to the guide cup 210 in a state of being in contact with the bottom 222. On the other hand, the outer peripheral surface of the lower flange 224 is fitted to the inner peripheral surface of the mold fixing cup 154 shown in FIG. The guide cup 210 is fixed in contact with the bottom of the mold fixing cup 154.

  In the same manner as shown in FIG. 17, the outer peripheral surface of the male mold 144 is fitted on the inner peripheral surface of the cylindrical portion 226 so as to be relatively movable in the axial direction and to be relatively rotatable around the axis. However, the relative movement of the male mold 144 with respect to the guide cup 210 (and thus the male mold 142 fixed to the guide cup 210) is formed on the guide pin 160 (see FIG. 17) of the male mold 144 and the cylindrical portion 226. It is regulated in cooperation with the first guide groove 232. As shown in FIG. 22 (b), the first guide groove 232 generally extends in the axial direction from the upper end surface of the cylindrical portion 226 toward the bottom portion 222. The first guide groove 232 is open at the upper end surface of the cylindrical portion 226.

  As enlarged in FIG. 24, the bottom surface of the first guide groove 232 has a first portion 240, a second portion 242, a third portion 244, and a fourth portion 246. Each of the first portion 240 and the fourth portion 246 has a downwardly convex arc shape and has a shape that partially complements the outer peripheral surface of the guide pin 160.

  In particular, the first part 240 is important to prevent the male mold 144 from adhering to the female mold 144, while the fourth part 246 adheres to the male mold 144 adhering to the female mold 142. Important to allow. Thus, the fourth portion 246 is closer to the female die 142 than the first portion 240.

  The second portion 242 is a straight portion that obliquely connects the first portion 240 and the upper end portion of the third portion 244, and has a slope (an example of the aforementioned “second slope”) with which the guide pin 160 contacts. This slope breaks down the axial centrifugal force (downward force) acting on the male mold 144 during revolution by the stirrer 40 and converts the axial centrifugal force into rotational force acting on the male mold 144. The second portion 242 is inclined in a direction approaching the fourth portion 246 with respect to an imaginary straight line extending in the circumferential direction of the cylindrical portion 226 from the first portion 240. The third portion 244 is a straight portion extending perpendicularly from the fourth portion 246 in a direction away from the female die 142.

  As shown in FIG. 22 (b), the movable member 212 has a cylindrical portion 250, and an upper flange 252 protrudes radially outward from the bottom of the cylindrical portion 250. At the outer peripheral edge of the upper flange 252, notches 254 penetrating the upper flange 252 in the thickness direction are respectively formed as air circulation holes at a plurality of locations separated in the circumferential direction. The outer peripheral surface of the upper flange 252 is fitted to the inner peripheral surface of the mold fixing cup 154 shown in FIG. 17 so as to be relatively movable in the axial direction and to be relatively rotatable around an axis.

  The upper flange 252 is located above the lower flange 224. The upper flange 252 and the lower flange 224 cooperate with each other to perform the same function as the spacer 152 shown in FIG.

  As shown in FIG. 22B, the outer peripheral surface of the cylindrical portion 226 of the guide cup 210 is fitted on the inner peripheral surface of the cylindrical portion 250 of the movable member 212 so as to be relatively movable in the axial direction and relatively rotatable around the axis. United. The guide cup 210 acts as a stationary member relative to the movable member 212. An example of the material which comprises this movable member 212 is POM.

  However, the relative movement of the movable member 212 with respect to the guide cup 210 is a second guide formed in the cylindrical portion 226 of the guide cup 210 in the thickness direction, as shown in FIG. Grooves (two in the present embodiment, facing each other in the diametrical direction) 260 and guide pins 262 fixed in a radially extending posture to the cylindrical portion 250 of the movable member 212 (in the present embodiment) (2) are regulated in cooperation with each other so as to face each other in the diametrical direction.

  As shown in FIG. 22C, the second guide groove 260 is generally V-shaped as a whole. FIG. 22C is a view of the second guide groove 260 as viewed from the outside in the radial direction of the guide cup 210. FIG. On the other hand, FIG. 22 (b) is a view of the first guide groove 232 formed in the cylindrical portion 226 of the guide cup 210 as viewed from the inside in the radial direction of the guide cup 210. Further, FIGS. 23 to 26 are views when the first guide groove 232 and the second guide groove 260 are both viewed from the inside in the radial direction of the guide cup 210.

  As shown in FIG. 23, the guide pin 262 is slidably fitted in the second guide groove 260, and the guide pin 262 (movable member 212) is in the second guide groove 260 (guide cup 210). It is possible to move relative to it. Further, since the second guide groove 260 has a closed groove shape, the second guide groove 260 and the guide pin 262 cooperate with each other to limit the relative movement of the movable member 212 with respect to the guide cup 210. Not only in the axial direction but also in the circumferential direction.

  As shown enlarged in FIG. 23, the second guide groove 260 is a first portion 270 which is a straight portion extending obliquely downward from the upper end, and a second portion 272 extending perpendicularly from the lower end of the first portion 270. And a third portion 274, which is a straight portion extending obliquely upward from the upper end of the second portion 272.

  The first portion 270 corresponds to one of two arms of the letter V that approximates the entire shape of the second guide groove 260, while the third portion 274 corresponds to the other arm. . The second portion 272 connects the first portion 270 and the third portion 274 to each other. The first to third portions 270, 272 and 274 are arranged in order along one rotational direction of the guide cup 210. The height of the upper end of the third portion 274 is higher than the upper end of the first member 270.

  The first portion 270 decomposes a downward force acting on the movable member 212 (the axial centrifugal force acting on the movable member 212 by revolution minus the elastic force of the spring 280), It has a slope (a lower surface of the first portion 270, which is an example of the above-mentioned "first slope") to be converted into the rotational force of the movable member 212. The third portion 274 decomposes the upward force (the elastic force of the spring 280 minus the axial centrifugal force) acting on the movable member 212, and part of it is converted to the rotational force of the movable member 212. It has a slope to be converted (an upper surface of the third portion 274, another example of the above-mentioned "first slope"). The rotational force generated by the first portion 270 and the rotational force generated by the third portion 274 have the same orientation.

  FIG. 23 shows that the guide pin 262 is at position A, that is, at the upper end of the first portion 270, and FIG. 24 shows that the guide pin 262 is at position B (the lower end of the movable member 212. Position), ie at the lower end of the first portion 270, and FIG. 25 shows that the guide pin 262 is at the position C, ie at the upper end of the second portion 272. And FIG. 26 shows that the guide pin 262 is at the position D, that is, at the upper end of the third portion 274. FIG. 22B shows that the guide pin 262 is at position D (upper end position of the movable member 212).

  As shown in FIG. 22 (b), a coiled spring 280 which is an example of an elastic member is disposed between the guide cup 210 and the movable member 212. In the present embodiment, a spring 280 is arranged to coaxially surround the cylindrical portion 226. Further, the spring 280 is supported at the lower end thereof on the upper surface of the lower flange 224, while the upper end of the spring 280 is supported on the lower surface of the upper flange 252 via the retainer 282. The spring 280 always biases the movable member 212 with respect to the guide cup 210 in a direction away from the guide cup 210 in the axial direction. However, the approach / separation limit of the movable member 212 with respect to the guide cup 210 differs depending on the rotational direction relative position of the guide pin 262 in the second guide groove 260, and accordingly, the rotational direction relative to the guide cup 210 of the movable member 212. It depends on the position.

  As shown in FIG. 22 (b), an engaging portion 290 is formed on the cylindrical portion 226 of the movable member 212. The engaging portion 290 moves integrally with the movable member 212, and as shown in FIG. 23, the guide pin 160 apparently changes the bottom shape of the first guide groove 232, thereby the guide pin Control the position of 160.

  The initial position of the guide pin 262 is the position A shown in FIG. From this state, the mold unit 200 is rotated and revolved by the stirrer 40. As a result, when the axial centrifugal force acting on the movable member 212 increases from 0 and reaches over the preload of the spring 280 shown in FIG. Due to the effect of the slope of the first portion 270, it descends while rotating in one direction. As a result, the guide pin 262 moves from position A to position B. In FIG. 22B, the most extended state (position D of the guide pin 262) of the spring 280 is indicated by a solid line, and the most compressed state (position B of the guide pin 262) is indicated by a broken line.

  Thereafter, when the revolution speed of the mold unit 200 changes from an increase (or a constant speed) to a decrease, the axial centrifugal force of the movable member 212 decreases, and as a result, the movable member 212 is raised by the elastic force of the spring 280. As a result, the guide pin 262 moves from position B to position C. Subsequently, due to the effect of the slope of the third portion 274 of the second guide groove 260, the guide pin 262 ascends while rotating in the same direction as the one direction. Thereby, the guide pin 262 moves from the position C to the position D.

  As shown in FIG. 23, the engagement portion 290 generally includes a first portion 300 extending parallel to the circumferential direction of the cylindrical portion 226 and a second portion 302 extending in an inclined direction with respect to the circumferential direction of the cylindrical portion 226. And a third portion 304 forming a notch (recess).

  As shown in FIG. 23, at the position A of the guide pin 262, the first portion 300 of the engagement portion 290 looks like the first portion 240 of the first guide groove 232, and the male mold 144 molds the female mold 142. Change so as to be more reliably blocked. Specifically, the first portion 300 lifts the guide pin 160 (male mold 144).

  Furthermore, at the position A of the guide pin 262, the third portion 304 of the engagement portion 290 may closely adhere to the male die 142 while the third die 304 of the first guide groove 232 looks over the shape of the fourth portion 246. Change to be more reliably blocked. Specifically, the third portion 304 apparently narrows the groove width of the third portion 244 of the first guide groove 232 so that the guide pin 160 enters the third portion 244 and the fourth portion 246 To prevent the male mold 144 from coming into close contact with the female mold 142.

  As shown in FIG. 24, at the position B of the guide pin 262, the engagement portion 290 descends and rotates in the direction approaching the first portion 240 of the first guide groove 232 from the position A. . At this time, the first portion 300 of the engaging portion 290 permits the guide pin 160 to contact the first portion 240 of the first guide groove 232, and the third portion 304 causes the guide pin 160 to be a first guide. It is allowed to descend along the third portion 244 of the groove 232. Because the third portion 304 is retracted in the rotational direction from the position of the groove of the third portion 244 of the first guide groove 232, the guide pin 160 enters the third portion 244 and enters the fourth portion 246. This is because it is permitted that the male mold 144 closely comes in contact with the female mold 142.

  At this stage, the guide pin 160 may get over the convex portion between the first portion 240 and the second portion 242 in the first guide groove 232, and the male die 142 may come into close contact with the female die 142. However, there is a possibility that the guide pin 160 can not get over the convex portion, and as a result, the male die 142 does not adhere to the female die 142.

  As shown in FIG. 25, at the position C of the guide pin 262, the engaging portion 290 ascends from the position B, and as a result, the first portion 300 and the second portion 302 of the engaging portion 290 The convex portion between them pushes up the guide pin 160 and helps the guide pin 160 to get over the convex portion of the first guide groove 232. At this stage, the male mold 142 may be in close contact with the female mold 142, but the male mold 142 may not be in close contact with the female mold 142.

  As shown in FIG. 26, at the position D of the guide pin 262, the engagement portion 290 ascends and rotates in the direction approaching the first portion 240 of the first guide groove 232 from the position C. . During the movement of the guide pin 262 from the position C to the position D, the first portion 300 and the second portion 302 retract with respect to the guide pin 160, so the guide pin 160 is located in the space in the third portion 304 . As a result, by the time the guide pin 262 reaches the position D, the guide pin 160 passes the slope of the second portion 242 and descends along the third portion 244. At this stage, the male die 144 is moved by the axial centrifugal force to be in close contact with the female die 142.

  In FIG. 27A, an example of a pattern in which the revolution speed of the mold unit 200 changes with time under the control of the stirrer 40 without using the brake 94 is represented by a graph.

  As shown in FIG. 27A, during the period from time t0 to t1, the revolution speed increases from zero, whereby the axial centrifugal force of the movable member 212 increases from zero. During this period, the revolution speed reaches and exceeds the threshold value V0, but the guide pin 262 is held at the position A shown in FIG. When the revolving speed exceeds the threshold value V0, the axial centrifugal force of the movable member 212 overcomes the elastic force of the spring 280. As a result, the guide pin 262 is shown in FIG. 24 from the position A shown in FIG. Move to position B.

  Thereafter, during the period from time t1 to time t2, the revolution speed decreases, whereby the axial centrifugal force of the movable member 212 also decreases. During this period, when the elastic force of the spring 280 overcomes the axial centrifugal force of the movable member 212, the guide pin 262 moves from the position B shown in FIG. 24 to the position C shown in FIG. It moves from position C to position D shown in FIG. The male mold 144 is prevented from coming into close contact with the female mold 142 until just before this position D, but just before this position D, the male mold 144 is allowed to come into close contact with the female mold 142.

  Subsequently, the revolution speed increases during a period from time t2 to t3. Thereafter, the revolution speed is maintained for a period from time t3 to t4. Subsequently, during the period from time t4 to t5, the revolving speed decreases to zero. Thus, one control cycle for the revolution speed is completed.

  FIG. 27B is a graph showing another example of the pattern in which the revolution speed of the mold unit 200 changes with time under the control of the stirrer 40 without using the brake 94.

  As shown in FIG. 27 (b), the revolution speed increases from 0 during the period from time t0 to t1. During this period, the revolution speed does not exceed the threshold value V0. As a result, the guide pin 262 is held at the position A. Thereafter, the revolution speed is maintained for a period from time t1 to t2. Subsequently, during the period from time t2 to t3, the revolution speed increases again. During this period, when the revolution speed exceeds the threshold value V0, the axial centrifugal force of the movable member 212 overcomes the elastic force of the spring 280, and as a result, the guide pin 262 moves from position A to position B .

  Thereafter, the revolution speed decreases in the period from time t3 to t4. During this period, when the elastic force of the spring 280 overcomes the axial centrifugal force of the movable member 212, the guide pin 262 moves from the position B to the position C, and then moves from the position C to the position D. The male mold 144 is prevented from coming into close contact with the female mold 142 until just before this position D, but just before this position D, the male mold 144 is allowed to come into close contact with the female mold 142.

  Subsequently, the revolution speed is maintained during the period from time t4 to t5. Thereafter, during the period from time t5 to time t6, the revolution speed decreases to zero. Thus, one control cycle for the revolution speed is completed.

  Another example of the pattern in which the revolution speed of the mold unit 200 changes with time under the control of the agitator 40 without using the brake 94 is graphically represented in FIG. In this example, the threshold value V0 is set to a speed closer to 0 than the two previous examples.

  As shown in FIG. 28, during the period from time t0 to t1, the revolution speed increases from zero. During this period, when the revolution speed exceeds the threshold value V0, the axial centrifugal force of the movable member 212 overcomes the elastic force of the spring 280, and as a result, the guide pin 262 moves from position A to position B . Thereafter, the revolution speed is maintained for a period from time t1 to t2.

  Subsequently, the revolution speed decreases during a period from time t2 to t3. During this period, when the elastic force of the spring 280 overcomes the axial centrifugal force of the movable member 212, the guide pin 262 moves from the position B to the position C, and then moves from the position C to the position D. The male mold 144 is prevented from coming into close contact with the female mold 142 until just before this position D, but just before this position D, the male mold 144 is allowed to come into close contact with the female mold 142. In this example, due to the lower revolution speed than the two previous examples, ie, the axial centrifugal force smaller than the two examples, the male mold 144 adheres to the female mold 142 at a lower speed than the two examples. Plunging into the material in female mold 142 with air entrapped in mold 144 is suppressed.

  Thereafter, during the period from time t3 to time t4, the motor 50 is alternately repeated between the acceleration mode and the constant speed mode, whereby the revolution speed has a gentle slope than that during continuous execution of the acceleration mode. To increase. As a result, the axial centrifugal force acting on the male mold 144 also increases with a gentle gradient, which also suppresses the mixing of air into the material.

  Subsequently, the revolution speed is maintained during the period from time t4 to t5. Thereafter, during the period from time t5 to time t6, the revolution speed decreases to zero. Thus, one control cycle for the revolution speed is completed.

  In addition, in the present embodiment, in the second guide groove 260, the position B, the position C, and the position D are not aligned on the same straight line, but may be aligned on the same straight line. Because the movement of the guide pin 262 from the position A to the position B, the third portion 304 is retracted in the rotational direction from the position of the groove of the third portion 244 of the first guide groove 232, whereby the guide pin 160 is This is because it is permitted to enter the third portion 244 and approach the fourth portion 246 so that the male mold 144 is in close contact with the female mold 142.

  Although some of the embodiments of the present invention have been described above in detail based on the drawings, these are only examples, and based on the knowledge of those skilled in the art, including the aspects described in the section of the [Summary of the Invention]. It is possible to carry out the present invention in other forms with various modifications and improvements.

Claims (4)

A method of forming a product by rotating a forming die, wherein
A first step of filling the mold with a material;
A second step of imparting a rotational movement to the mold, thereby agitating and degassing the material, and thereby rotationally molding the product;
A third step of starting the rotational molding from an open state of the mold;
A fourth step of transitioning the mold during rotational movement from an open state to a closed state after the start of the rotational molding. The mold includes a female part and a male part,
The female and male parts are positioned to cooperate with one another to form a mold cavity having a predetermined shape in the closed state,
The molding method according to claim 1, wherein the female part and the male part are positioned so as to be released from each other in the open state, thereby not forming the mold cavity in cooperation with each other.   The molding method according to claim 1, wherein the material is a liquid synthetic resin.   The molding method according to any one of claims 1 to 3, wherein the rotational movement is a planetary movement.

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