JP4419686B2 - Molding method for composite parts - Google Patents

Description

  The present invention relates to a molding method in which metal parts such as metal circuit lines and metal terminals are fixed in a resin, and is particularly effective in a method for manufacturing electrical parts such as connectors and relays.

  Conventionally, as disclosed in JP-A-60-253520 and JP-A-7-108543, composite parts having metal parts have been mainly used for electric parts. A method of cutting a piece and injecting and curing a resin is known. In this type of molding method, generally, as described in JP-A-60-253520, the punch is disposed at a location away from the cavity in the mold, and a portion for injecting and curing resin and a metal The part which cut | disconnects a piece was a separated structure. Japanese Patent Application Laid-Open No. 7-108543 discloses that a cylindrical guide is provided, and a resin is injected and cured in a state where the bottom surface of the punch is pressed against the punch, thereby enabling efficient production of parts. .

However, in the case of Japanese Patent Application Laid-Open No. 60-253520, in the case of molding a composite part in which the resin injection / curing part and the cut part of the metal piece are hardly separated, the metal piece is fixed. It is difficult to provide this part in the mold, and even if it can be provided, the thickness of the mold in the vicinity of that part will be reduced, so the mold will be plastically deformed during molding when high pressure is applied, such as injection molding. There was a problem to do.

In the case of Japanese Patent Application Laid-Open No. 7-108543, since the resin is injected and cured with the bottom surface of the punch pressed against the insert part, the resin adheres to the bottom surface of the punch and shortens the life of the punch. There was a problem to do. Furthermore, since the vicinity of the cutting part is fixed with the cylindrical guide, the part fixed with the cylindrical guide of the insert part is exposed after sealing without being sealed, and the insert part is exposed. There were also problems in terms of adhesion strength and reliability.
JP 60-253520 A JP-A-7-108543

  The present invention has been invented in view of the above-described background art, and its object is to provide a method for forming a composite part that does not require the thickness of the mold to be unnecessarily thin and can extend the life of the punch. That is.

In order to solve the above problems, the present invention comprises a functional part remaining in a composite part, a frame part for use in positioning or transporting into a mold, and a cutting part that is a boundary part between the functional part and the frame part. Placing the inserted part in the mold, fixing the functional part of the insert part in the mold by closing the mold, and the frame part near the cutting part of the fixed insert part to the mold. independently a cutting step of a movable insert part by pressing a punch bottom cleaves at the cleavage site, further depressing the punch while deforming the frame portion of the insert part with a punch bottom surface Te, frame site cavity is the deformation a cavity forming step of forming a cavity in the mold and the punch side is not a punch bottom surface to be positioned outside of, calibration It includes a molding process for molding a composite part having a functional part of an insert part by injecting and curing resin to the tee, and a mold opening process for removing the punch from the cavity and opening the mold to take out the composite part. It is to mold composite parts.

In the method for molding a composite part according to the present invention, a functional part remaining in the composite part, a frame part for use in positioning or conveying in the mold, and a cutting part that is a boundary part between the functional part and the frame part are provided. After placing the insert part in the mold and fixing the insert part in the mold by closing the mold, the insert part is pressed by pressing the bottom of the punch that can move independently of the mold near the cutting part of the insert part. cut, the frame portion of the insert part further depress the punch while deforming punch bottom to form a cavity in the mold and the punch side is not a punch bottom surface so that the frame portion to be the deformation is located outside the cavity After that, the mold is opened by injecting and curing resin into the cavity and taking out the composite part. There is no need to thin the part. In addition, since the bottom surface of the punch is disposed outside the cavity when the resin is injected, it is possible to prevent the resin from adhering to the bottom surface of the punch and to extend the life of the punch.

  1-5 has shown the shaping | molding method of the composite component 5 which is one Embodiment corresponding to both Claim 1 * 2 of this application. First, the molding apparatus will be described. The molding apparatus used in this embodiment is a mold 10 for fixing the insert part 1 inside, and injecting resin into the mold 10, and the inside of the mold 10 can be moved independently from the mold 10 in the vertical direction. It is provided with a punch 40 for cutting one part of the insert part 1 disposed in the mold 10.

  The insert part 1 used in this embodiment is formed by punching a copper plate having a thickness of 0.12 mm to make a hole, and then making a part into a protrusion-shaped portion by pressing. A plurality of functional parts 25 constituted by parts and flat parts connecting them, a frame part 30 which is a part other than the functional part 25 including the outer periphery, and a plurality located at the boundary between the functional part 25 and the frame part 30 And a cutting portion 35. (Figure 2)

  In addition, the mold 10 used in this embodiment includes a lower mold 11 that is a fixed mold and an upper mold 12 that is a movable mold. It has a structure that can be closed.

  The lower mold 11 is composed of a gate groove 19 that constitutes a part of the gate when resin is injected, a cavity lower portion 15 that is connected to the gate groove 19 and whose upper surface becomes the lower wall of the cavity 55 when resin is injected, In order to arrange the functional part 25 of the insert part 1 to be left in the part 5 above the cavity lower part constituting part 15, the functional part composed of a plurality of convex portions provided on both sides of the cavity lower part constituting part 15 In order to secure a moving region of the punch 40 for cutting the placement part 13 and one part of the insert part 1, it has a cross-sectional shape substantially the same as the shape of the bottom face 45 of the punch, and is lower than the part 15 for configuring the cavity lower part And a punch relief groove 17 whose bottom surface is located below. (Figure 1)

  The upper mold 12 is located immediately above the cavity constituting part of the lower mold 11, and the upper part constituting part 16 serving as the upper wall of the cavity 55 and the functional part 25 of the insert part 1 are inserted into the lower mold 11 when resin is injected. In order to be sandwiched between and fixed to the functional part arranging part 13, it is provided on both sides of the cavity upper part 16 and the bottom surface has a concave shape following the protruding part of the functional part 25 of the insert part 1. A functional part fixing part 14, a punch slide hole 18 which is provided to enable the slide movement of the punch 40 in the vertical direction and has a sectional shape substantially the same as the shape of the bottom face 45 of the punch, and a lower mold 11 is provided with a resin injection port 20 (FIG. 4) that is a vertical through hole that is positioned directly above the 11 gate grooves 19 and becomes a part of the gate during resin injection. (Figure 3)

  The punch 40 is independent of the upper die 12 and can be moved and controlled in the vertical direction. The punch 40 has a driving mechanism (not shown) different from the driving mechanism of the upper die 12 and a cavity lower component part of the lower die 11. Reduces wear when cutting the insert part 1 and a tip portion having a prismatic shape in which a cross section following the concave and convex shape formed by the side surfaces of the 15 side surfaces and the functional site arranging portion 13 is vertically extended. Therefore, a punch bottom surface 45 is provided which is hard-worked and has an inclined surface inclined with respect to a plane connecting the cavity lower portion constituting portion 15 and the outer portion of the punch escape groove 17. Further, the punch 40 has a clearance of 0.003 mm to 0.010 mm from the side surface of the cavity lower portion constituting portion 15 and the side surface of the functional portion arranging portion 13 of the lower die 11, and the punch slide hole 18 of the upper die 12. And, it has a structure that can move in the punch escape groove 17 of the lower mold 11 in the vertical direction. (Fig. 5 (A))

  Next, a method for forming the composite part 5 will be described. In this embodiment, a functional part 25 remaining in the composite part 5, a frame part 30 for use in positioning or conveying into the mold 10, and a cutting part 35 at the boundary between the functional part 25 and the frame part 30. An arrangement step of arranging the provided insert part 1 in the mold 10, a fixing step of fixing the functional part 25 of the insert part 1 in the mold 10 by closing the mold 10, and a cutting part 35 of the fixed insert part 1 A cutting process in which the insert part 1 is cut at the cutting part 35 by pressing a punch bottom surface 45 that can move independently of the mold 10 against the frame part 30 in the vicinity, and a punch while deforming the frame part 30 of the insert part 1 40 is further pushed down to form a cavity 55 between the mold 10 and the punch side surface 50, and a resin is applied to the cavity 55. A molding process for molding the composite part 5 having the functional part 25 of the insert part 1 by injection and curing, and a mold opening process for extracting the punch 40 from the cavity 55 and opening the mold 10 to take out the composite part 5. By doing so, the composite part 5 is molded. Thereby, it is not necessary to reduce the thickness of the mold 10 more than necessary, and the resin does not adhere to the punch bottom surface 45, so that the life of the punch 40 can be extended.

  Furthermore, a part of the frame part 30 of the insert part 1 is plastically deformed by pushing down the punch 40 during the cavity forming process, so that the frame part 30 of the insert part 1 is shaped before the cutting process after the mold is opened. As a result, a spring back is generated to return to the point, and the composite part 5 is prevented from being damaged. Details of each of these steps will be described below.

  FIG. 2 is a perspective view of a main part showing the stage of the arrangement process. As shown in FIG. 2, in the arrangement step in this embodiment, the frame part 30 connected to the cutting part 35 of the insert part 1 is located outside the functional part arranging part 13 of the lower mold 11 and the punch relief groove 17 of the lower mold 11. The insert part 1 is placed in the lower mold 11 so as to be placed between the parts and so that the protrusion-shaped part of the functional part 25 of the insert part 1 faces upward. At this time, the cutting part 35 of the insert part 1 is on the outer periphery of the upper surface of the functional part arranging part 13 of the lower mold 11, and the functional part 25 of the insert part 1 is above the functional part arranging part 13 of the lower mold 11. However, although not shown in the drawing, a positioning hole is provided in a part of the frame part 30 of the insert part 1 and a positioning pin is provided in the lower mold 11 so that the positioning pin of the lower mold 11 is provided. The positioning accuracy of the insert part 1 with respect to the lower mold 11 is maintained within 0.01 mm by inserting the positioning hole of the insert part 1 into the insert part 1.

  FIG. 3 is a perspective view of the main part showing the stage of the fixing process. As shown in FIG. 3, the fixing process in this embodiment is performed by moving the upper part 12 downward in the insert part 1 arranged in the lower mold 11, and the protrusion shape of the functional part 25 of the insert part 1. The part is between the functional part fixing part 14 of the upper mold 12 and the functional part arranging part 13 of the lower mold 11, and the outer peripheral part of the frame part 30 is outside the punch slide hole 18 of the upper mold 12 and the lower mold 11. The insert part 1 is fixed in the mold 10 by applying a load of 2000 to 5000 N to the upper mold 12 between the outer portions of the punch relief grooves 17. At this time, the upper surface of the cavity lower component part 15 located between the bottom surface of the cavity upper component part 16 located between the functional part fixing parts 14 of the upper mold 12 and the functional part arrangement part 13 of the lower mold 11. Are opposed to each other with a gap through which resin can be injected.

  FIG. 4 is an overall perspective view showing the steps of the cutting process. As shown in FIG. 4, the cutting process in this embodiment is performed in such a manner that the punch 40 whose tip is disposed in the punch slide hole 18 of the upper mold 12 which is closed is separated from the drive mechanism of the upper mold 12. Using a drive mechanism (not shown), the punch bottom surface 45 is pressed against the frame part 30 of the insert part 1 by moving downward. Further, the punch 40 is further moved downward to be a part between the punch bottom face 45 and the functional part arranging part 13 of the lower mold 11, that is, a boundary part between the functional part 25 of the insert part 1 and the frame part 30. The insert part 1 is cut at the cutting part 35 by applying a load of 50000 N or more to the punch 40, and the functional part 25 and the frame part 30 of the insert part 1 are separated.

  5A and 5B are a perspective view and a cross-sectional view of the main part showing the stage of the cavity forming process. As shown in FIG. 5 (A), in the cavity forming step in this embodiment, the punch 40 is moved downward even after the cutting part 35 of the insert part 1 is cut, so that the functional part of the lower mold 11 is arranged. This is performed by pushing down the frame part 30 that has bridged between the part 13 and the outer part of the punch relief groove 17 of the lower mold 11. The frame part 30 sandwiched between the outer part of the punch slide hole 18 of the upper mold 12 and the outer part of the punch relief groove 17 of the lower mold 11, the functional part arranging part 13 of the lower mold 11, and the lower mold 11 The insert part 1 is plastically deformed in the vicinity of the boundary with the frame part 30 that has bridged between the outer part of the punch relief groove 17. Thereby, it is possible to prevent the frame part 30 of the insert part 1 from returning to the shape before the cutting process after the mold is opened and damaging the composite part 5. Further, as shown in FIG. 5 (B), the punch 40 is moved downward until the bottom surface 45 of the punch is lower than the upper surface of the cavity lower portion constituting portion 15 of the lower die 11. The cavity 55 including the functional part 25 of the insert part 1 is simultaneously formed by the bottom surface of the cavity upper part 16, the upper surface of the cavity lower part 15 of the lower mold 11, and the punch side surface 50. .

  In the molding process in this embodiment, a thermosetting resin liquid is poured from the resin inlet 20 (FIG. 4) of the upper mold 12, and the poured thermosetting resin liquid is passed through the gate groove 19 of the lower mold 11. It is injected into a cavity 55 formed by the bottom surface of the cavity upper part 16 of the upper die 12, the upper surface of the cavity lower part 15 of the lower die 11, and the punch side surface 50. Then, the composite part 5 (FIG. 6) provided with the functional part 25 of the insert part 1 and the resin part 60 is shape | molded by hardening | curing a thermosetting resin liquid with the heat | fever transmitted from a type | mold.

  In the mold opening process in this embodiment, the punch 40 is moved upward until the punch bottom surface 45 is above the bottom surface of the cavity upper component part 16 of the upper mold 12, and the punch 40 is removed from the cavity 55. After pulling out, the upper mold 12 is moved upward to perform mold opening. Thereafter, an ejector pin (not shown) provided in the cavity lower portion 15 is moved upward to take out the composite part 5. Since the upper mold 12 and the punch 40 are moved upward at different timings at the time of mold opening as described above, the resistance at the time of mold release applied to the composite part 5 at the time of mold opening can be dispersed. Chipping of the composite part 5 due to mold release resistance can be prevented.

In this way, the composite part 5 including the insert part 1 is molded. However, since the punch side surface 50 forms one surface of the cavity 55, it is not necessary to make the mold 10 portion between the punch 40 and the cavity 55 thin. In addition, since the bottom surface 45 of the punch is disposed outside the cavity 55 when the resin is injected, it is possible to prevent the resin from adhering to the bottom surface 45 of the punch, and the life of the punch 40 can be extended.
In the above embodiment, the resin constituting the resin portion 60 of the composite component 5 is a thermosetting resin, but a thermoplastic resin may be used.

The lower mold | type (A) used for one Embodiment of this invention is a whole perspective view, (B) is a perspective view of the principal part. The perspective view of the principal part which shows the step of the arrangement | positioning process in one Embodiment of this invention. The perspective view of the principal part which shows the step of the fixing process in one Embodiment of this invention. The whole perspective view which shows the step of the cutting process in one Embodiment of this invention. (A) is a perspective view of the principal part, (B) is sectional drawing of the principal part which shows the step of the cavity formation process in one Embodiment of this invention. The perspective view of the composite component produced in one Embodiment of this invention.

Explanation of symbols

1 Insert Part 5 Composite Part 10 Mold 25 Functional Part 30 Frame Part 35 Cutting Part 40 Punch 45 Punch Bottom 50 Punch Side 55 Cavity

Claims (3)

A method for forming a composite part, comprising the following steps.
(1) a functional site remaining in the composite part, a frame portion position for use in positioning or transport to the mold, cutting the site is the boundary portion of the functional sites and the frame part, the insert part having a arrangement step of arranging in a mold.
(2) A fixing step of fixing the functional part of the insert part in the mold by closing the mold.
(3) to a frame portion of the cleavage site near the fixed insert part, as the cutting engineering for cutting the insert part at the cleavage site by pressing the bottom of the independent movement available-punch relative to the mold.
(4) The punch is further pushed down while the frame portion of the insert part is deformed at the bottom surface of the punch, and a cavity is formed by the die and the side surface of the punch that is not the bottom surface of the punch so that the deformed frame portion is positioned outside the cavity. Cavity formation process.
(5) by injecting and curing the resin into the cavity, forming step of forming a multi-focus parts that have a functional site of the insert part.
(6) A mold opening process in which the punch is removed from the cavity and the mold is opened to take out the composite part.   The method for forming a composite part according to claim 1, wherein the cavity forming step plastically deforms a frame portion of the insert part by pressing down a punch. In the insert part, the functional part and the frame part are continuous at a plurality of cutting parts,
3. The method of forming a composite part according to claim 1, wherein, in the cutting step, the plurality of cutting sites are simultaneously cut.

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