JP6473786B1 - Insert molding method and mold for insert molding - Google Patents

Abstract

The present invention provides an insert molding method capable of suppressing the time and cost for manufacturing a mold and suppressing the energy required for processing the mold. In an insert molding method, in an insert material 2 having an injection molding region 22, only the injection molding region 21 is sandwiched between the movable mold 5 and the fixed mold 6, and the region 22 other than the injection molding region is movable. It includes a mold clamping process in which mold clamping is performed without being sandwiched between the side mold 5 and the fixed side mold 6 and an injection molding process in which the injection molding part 31 is formed only in the injection molding region 21. [Selection] Figure 2

Description

  The present invention relates to an insert molding method and a mold for insert molding, and more particularly, to an insert molding method for performing injection molding in a mold on a preformed insert material, and a mold used in the insert molding method.

  There is an insert molding method as a manufacturing method of a molded product having a high design property.

  The insert molding method is performed in the following steps. First, an insert material is preformed. Next, the preformed insert material is placed in a mold for injection molding. Next, heated resin that is an injection molding material is poured around the insert material. Next, after the resin is cooled and solidified, the insert-molded product is released.

  There exists a thing shown in patent document 1 as an insert molded article. In patent document 1, resin covers the whole rear surface of the transparent member which hits insert material.

Japanese Patent Laid-Open No. 2006-182866

  When the shape of the preformed insert material becomes complicated, the insert material comes into contact with the mold and is placed at an accurate position. Therefore, it is necessary to manufacture a mold according to the complicated shape. Therefore, high precision and small surface roughness are required for the mold. In addition, if the shape of the insert material changes, the mold must be manufactured again. For this reason, there is a problem that it takes time and cost to manufacture the mold, and energy required for manufacturing the mold also increases.

  Depending on the application of the insert-molded product, the surface of the insert material may not be covered with the injection-molded material in the portion that is three-dimensionally shaped by the preforming. Nevertheless, as in Patent Document 1, if the entire surface of the insert material is covered with the injection molding material, the insert molding product becomes heavy. For this reason, there are problems that the transportation cost increases and it is difficult to reduce the CO2 emission amount during transportation. Since the amount of the injection molding material used is large, it is necessary to melt the injection molding material in accordance with the amount of use, and there is a problem that it is difficult to reduce the CO2 emission amount in insert molding.

  Therefore, from the above points, the present invention suppresses the manufacturing time and cost of the mold, and can also suppress the energy required for the processing of the mold, the mold for insert molding, and the insert molding. An object of the present invention is to provide an insert molded product that can reduce the weight of the product and significantly reduce the amount of injection molding material used.

In order to solve the above-mentioned problem, the insert molding method according to claim 1 is an insert material having an injection molding region consisting of a range where the movable side mold or the fixed mold is in contact and a range surrounded by the contact range. A mold clamping process in which only the injection molding area is sandwiched between the movable mold and the fixed mold, and the area other than the injection molding area inside the mold is clamped in a non-contact state with the movable mold and the fixed mold. And an injection molding process in which the injection molding part is formed only in the injection molding region.

The insert molding method according to claim 2 is an insert material having an injection molding area, wherein only the injection molding area is sandwiched between the movable side mold and the fixed side mold, and the area other than the injection molding area inside the mold is the movable side mold. A mold clamping step for clamping the mold and the fixed mold in a non-contact state, and an injection molding in which an injection molding portion is formed only on the movable mold side surface or the fixed mold side surface in the injection molding region Process.

According to the insert molding method of claim 1 and 2, even if the shape of the preformed insert material is complicated, only the portion sandwiching the injection molding region of the movable side mold and the fixed side mold has high accuracy and What is necessary is just to satisfy requirements, such as small surface roughness. Further, even if the shape of the region other than the injection molding region of the insert material inside the mold is changed, it is not necessary to manufacture the mold again if the shape of the injection molding region of the insert material does not change.

  According to the insert molding method of claims 1 and 2, since the injection molded part is formed only in the injection molding region, the resin covers a part of the surface of the insert material. Therefore, it is possible to reduce the weight of the insert molded product and reduce the amount of the injection molded material used.

  Furthermore, according to the insert molding method of claims 1 and 2, in the mold clamping process, only the injection molding region of the insert material has to be pressed by the movable side mold and the fixed side mold, so the mold clamping force is low. An injection molding apparatus can be used. Therefore, it is possible to reduce the size of the injection molding apparatus and reduce the CO2 emission amount in insert molding.

The mold for insert molding according to claim 3 is used for insert molding of an insert material having an injection molding region consisting of a range where the movable side die or the fixed die is in contact and a range surrounded by the contact range. The movable side mold and the fixed side mold, the movable side mold and the fixed side mold, when the mold is clamped, the contact surface sandwiching only the injection molding region of the insert material, and the inside of the mold An area other than the injection molding area of the insert material can be accommodated in the movable mold and the stationary mold in a non-contact state.

According to the mold for insert molding of claim 3, the surface of the mold constituting the space that can accommodate the area other than the injection molding area of the insert material inside the mold has high accuracy and small surface roughness. Not required.

Further, the insert molding die according to claim 3 is different in the shape of the region other than the injection molding region of the insert material inside the mold, but various types of insert materials having the same shape of the injection molding region of the insert material. An injection molding part can be formed.

  Furthermore, in mold clamping, since the movable mold and the fixed mold may press only the injection molding region of the insert material, the mold for insert molding according to claim 3 is an injection molding apparatus having a low mold clamping force. Be available. Therefore, it is possible to reduce the size of the injection molding apparatus and reduce the CO2 emission amount in insert molding.

  The insert molding method according to claims 1 and 2 and the insert molding die according to claim 3 reduce time and cost for manufacturing the die, and also suppress energy required for processing the die. be able to. Further, the weight reduction of the insert-molded product can reduce the conveyance cost and reduce the CO2 emission amount during the conveyance. Furthermore, the CO2 emission amount in insert molding can be reduced by reducing the amount of injection molding material used.

It is a perspective view of the insert molded product which is one Embodiment of this invention, and shows the state which turned up the surface in which the injection molding part was formed. It is the schematic which shows the process of the insert molding method which is one Embodiment of this invention.

  Hereinafter, an insert molded product 1 according to an embodiment of the present invention will be described.

  The insert molded product 1 includes an insert material 2 and an injection molded part 3. In the insert molded product 1 of the present embodiment, the side on which the injection molded part 3 is formed is the back side, and the side on which the injection molded part 3 is not formed is the front side.

  The material of the insert material 2 can be selected from, for example, polyethylene terephthalate resin, polymethyl methacrylate resin, general-purpose plastic such as acrylonitrile / butadiene / styrene resin and polypropylene resin, and engineer plastic such as polycarbonate resin.

  The insert material may be a single material or a laminate obtained by laminating the material surface.

  The insert material 2 has an injection molding region 21 and a region 22 other than the injection molding region.

  The injection molding region 21 and the region 22 other than the injection molding region are formed in a preforming step of the insert material 2 described later.

  The insert material 2 is in the form of a sheet before the preforming step described later, and the thickness thereof is 0.1 mm to 1.0 mm. The sheet-like insert material 2 before the preforming step has flexibility.

  The injection molding area 21 is a flat surface.

  The region 22 other than the injection molding region has a three-dimensional solid shape. The three-dimensional solid shape protrudes from the back surface side of the insert molded product 1 toward the front surface side.

  The region 22 other than the injection molding region is in a state where the surface of the insert material 2 is exposed.

  In the back surface provided with the injection molding part 3 of the insert material 2, the area of the injection molding region 21 is in the range of 3% to 70% with respect to the total surface area.

  The insert material 2 is provided with the injection molding part 3 only in the injection molding region 21.

  The material of the injection molding part 3 can be selected from, for example, engineer plastics such as polycarbonate resin, and general-purpose plastics such as acrylonitrile / butadiene / styrene resin, polymethyl methacrylate resin, and polypropylene resin.

  The injection molding unit 3 is, for example, a boss that enables the insert molded product 1 to be screwed.

  Hereinafter, an insert molding die according to an embodiment of the present invention will be described with reference to FIG.

  The mold for insert molding includes a movable mold 5 and a fixed mold 6.

  When the movable side mold 5 is clamped, the abutment surface 51 that sandwiches only the injection molding region 21 of the insert material 2 and the region 22 other than the injection molding region of the insert material 2 are fixed to the movable side mold 5 and fixed. And a space 52 that can be accommodated without being sandwiched between the side molds 6.

  Similarly, when the mold 6 is clamped, the fixed-side mold 6 includes a contact surface 61 that sandwiches only the injection molding region 21 of the insert material 2 and a region 22 other than the injection molding region of the insert material 2. 5 and a space 62 that can be accommodated without being sandwiched between the stationary molds 6.

  The surface roughness Ra of the contact surface 51 of the movable mold 5 and the contact surface 61 of the fixed mold 6 is 1.6 or less.

  The surface constituting the space 52 of the movable mold 5 and the surface constituting the space 62 of the fixed mold 6 have a surface roughness Ra of 3.2 or more.

  The stationary mold 6 further includes a cavity 63 and a runner 64. The opening on the contact surface 61 side of the hollow portion 63 is blocked by the injection molding region 21 of the insert material 2 when the mold is clamped.

  The cavity 63 is filled with a molten injection molding material via a runner 64 formed in the fixing mold 6.

  The molten injection molding material is not injected into the space 52 of the movable mold 5 and the space 62 of the fixed mold 6.

  Hereinafter, an insert molding method according to an embodiment of the present invention will be described with reference to FIG.

  FIGS. 2A to 2C show a process of preforming the insert material 2. FIGS. 2D to 2G show the process of forming the injection molded part 3 on the insert material 2.

  First, as shown in FIG. 2A, the sheet-like insert material 2 is disposed between the preforming molds 4 and 4. The sheet-like insert material 2 may be heated and softened in advance.

  Next, as shown in FIG. 2B, the molds 4 and 4 for preforming are clamped to preform the insert material 2.

  Next, as shown in FIG. 2C, the insert material 2 is released from the preforming molds 4 and 4. The insert material 2 after the preforming has an injection molding region 21 and a region 22 other than the three-dimensional injection molding region.

  Next, as shown in FIG. 2 (d), the sheet-like insert material 2 is disposed between the movable mold 5 for insert molding and the fixed mold 6.

  Next, as shown in FIG. 2E, the movable mold 5 for insert molding and the fixed mold 6 are clamped. In mold clamping, the movable mold 5 and the fixed mold 6 may press only the injection molding region 21 of the insert material 2. Therefore, insert molding can be performed with an injection molding apparatus having a mold clamping force of 30% or less as compared with the case where the entire surface of the insert material is covered with the injection molding material.

  Next, as shown in FIG. 2 (f), the molten injection molding material is injected and filled into the cavity 63 through the runner 64. When the fixed mold 6 is cooled and the injection molding material is solidified in the cavity 63, the injection molding part 31 is obtained.

  Next, as shown in FIG. 2 (g), the insert-molded product 1 is released from the movable mold 5 and the fixed mold 6 for insert molding.

  In the said embodiment, although the insert molded product 1 demonstrated the case where the side in which the injection molding part 3 is formed is made into a back surface side, and the side in which the injection molding part 3 is not formed is made into the surface side, it is limited to this. It will never be done. In the insert molded product, the side on which the injection molded part is formed may be the front side, and the side on which the injection molded part is not formed may be the back side.

  Although the said embodiment demonstrated the case where the injection molding area | region 21 became a plane, it is not limited to this. As long as the injection molding part can be formed in the injection molding region, the injection molding region may be a curved surface.

  In the said embodiment, although the three-dimensional solid shape demonstrated the case where it protruded toward the surface side from the back surface side, it is not limited to this. The three-dimensional solid shape may protrude from the front surface side toward the back surface side.

  In the said embodiment, although the cylindrical injection molding part 3 is formed in six places in FIG. 1, it is not limited to this. In the insert molded product, the number and shape of the injection-molded parts may be freely changed according to the application.

  In the said embodiment, although the raw material of the insert material 2 and the raw material of the injection molding part 3 were illustrated, it is not limited to this. The material of the insert material and the material of the injection molding part can be freely selected as long as they can be insert-molded.

DESCRIPTION OF SYMBOLS 1 Insert molded product 2 Insert material 3 Injection molding part 4 Mold for preforming 5 Movable side mold 6 Fixed side mold 21 Injection molding area | region 22 Area | regions other than an injection molding area | region 31 Injection molding part 51 Contact surface 52 Space 61 Contact surface 62 Space 63 Cavity 64 Runner

Claims (3)

In an insert material having an injection molding area consisting of a range where the movable side mold or the fixed mold comes into contact and a range surrounded by the contact area, only the injection molding area is sandwiched between the movable side mold and the fixed side mold. A mold clamping step in which the area other than the injection molding area inside the mold is clamped in a non-contact state with the movable side mold and the fixed side mold,
An insert molding method comprising: an injection molding step in which an injection molding part is formed only in an injection molding region. In an insert material having an injection molding area, only the injection molding area is sandwiched between the movable mold and the fixed mold, and areas other than the injection molding area inside the mold are not in contact with the movable mold and the fixed mold. A mold clamping process for clamping in a state;
An insert molding method comprising: an injection molding step in which an injection molding portion is formed only on a movable mold side surface or a fixed mold side surface of an injection molding region. The movable side mold and the fixed side mold are used for insert molding of an insert material having an injection molding area composed of a range where the movable side mold or the fixed mold comes into contact and a range surrounded by the contact range. And
When the movable side mold and the fixed side mold are clamped, the abutment surface that sandwiches only the injection molding area of the insert material and the area other than the injection molding area of the insert material inside the mold are movable side molds. and a mold for insert molding, characterized in that the fixed mold and a space capable of accommodating a non-contact state.

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