KR830001206B1 - Manufacturing method of composite parts for insert or out insert molding - Google Patents

Abstract

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Description

Manufacturing method of composite parts for insert or out insert molding

1-8 are schematic diagrams illustrating various embodiments of the method of the present invention.

The present invention relates to a method of easily manufacturing insert or insert insert composite parts made of hard materials such as metals and synthetic resins with a high degree of accuracy.

Conventionally, composite parts made of hard materials such as synthetic resins and metals have been used as basic types in almost all fields of industry such as vehicles, electrical appliances, precision machinery and products, toys, furniture, office supplies, agricultural machinery and products.

These composite parts are in many cases manufactured by combining the basic parts manufactured separately, or in some cases by combining the parts during molding, for example in a process called "metal insert". Basic parts have been manufactured.

In recent years, even one hard substrate has been produced by one molding operation even for parts combined with a plurality of synthetic resin bodies. According to this process, integrated composite parts are obtained by mounting a warped substrate manufactured in a suitable shape by a press working method into a molding die and curing synthetic resin by pouring it into the mold. In such composite parts, the synthetic resin is bonded to the substrate by filling it in squared holes provided on the substrate. Since the relationship between the resin and the metal substrate is opposite to that of the conventional metal insert, this is called an outsert, which is widely used in tape recorders and watches (vo.1 26). , See “Plastic” in No. 12, pages 52,53).

Insert or out-art molding methods are very economical compared to the manufacture of composite parts by conventional assembly methods, but are still insufficient. That is, according to this method, the process of processing a hard material by a method such as pressing, cutting and the like to produce a composite of the processed hard material and synthetic resin has been performed separately. Therefore, as many machines and workers as these two steps are needed, and complicated steps have caused various problems.

For example, in assembling the inside of the molding machine with the hard material accurately, special care was required, and because of this error, the defect rate was high.

In addition, when the substrate is used as a raw material in the outsert method, for example, it is relatively easy to stack a large number of flat substrates on another substrate and send them to the molding machine automatically one after another. As for substrates with bends, special conveyors or similar devices are required for handling them. As a result, automation becomes very difficult.

The present invention is based on the idea that the mold part of a normal injection molding apparatus can also be used as a press molding machine, and when forming a synthetic resin stream, it is possible to perform the press working step which is most commonly used to process hard materials. As a result, the steps are simplified, accuracy and improvement can be achieved to a considerable extent, resulting in a reduction in product reject rates.

That is, the present invention is directed to a novel method for producing composite parts consisting of hard materials such as press-workable metals and synthetic resins such as thermoplastic resins that can be cured in a cavity formed in a template.

Therefore, this is the whole or one of the steps of providing a shape required to functionally or to compound the hard material and the synthetic resin in the hard material when making a composite part by putting the synthetic resin inside the mold already assembled into the hard material and curing it. The blowing is characterized by being carried out by moving the mold, core, pin, etc., when the mold is opened, the mold is opened, or the resin is poured and cured.

As described above, the hard material used in the present invention is a material that can be processed through movement of a template or the like, and metal plates such as cold rolled steel sheets and aluminum plates are most preferable, and thermosetting resin plates can also be used. .

In special cases, a lump rod such as synthetic resins or aluminum may be used.

Regarding the synthetic resins to be produced in the composite article, thermoplastic resins such as polyacetal are most preferred, but thermosetting resins may be used.

There is no particular limitation on the process performed by the press operation, but simple deformation processing such as cutting of the substrate from bending, shallow brawing, and continuous materials, etc., is the easiest and, conversely, 1 Blanking operations, such as those cut by additional processing operations, require steps for discharging the cutouts to be obtained, so that this processing can also be used as long as this does not greatly complicate the steps or the structure of the mold.

In the processing of rigid substrates, pre-processing can be carried out at the stage of the present invention starting with materials in the form of lumps, rods, plates, etc., and ending with obtaining the desired shape.

In addition, processing which complicates a part of a mold such as a blanking or a press that requires a high speed or high load press may be performed separately as in the case of the conventional process, and only other processing may be performed in the process of the present invention.

In either of these cases, the shape of the hard material in the step of compounding parts is simplified, and automation becomes easier than in the conventional process.

In addition, in the case of the conventional method, special attention has been paid to the positioning of hard materials in order to ensure the accuracy as a whole, but in the case of the present invention, the accuracy is achieved by performing the machining of parts requiring special and strict positioning relations at the stage of the present invention. Is easily improved.

In addition, in the outsert molding of a substrate having cutouts and the like, deformation occurs in the transverse direction due to the molding pressure of the resin, but such deformation can be avoided by providing cutouts in the steps of the present invention. In addition, when hard materials are pre-processed into complex shapes, they are limited in the cavity structure for the synthetic resin to be compounded therein, but in the case of the equipment, it is possible to process hard materials during or after filling the resin to a considerable extent. You can reduce the limit. In this case, the synthetic resin can also be processed at the same time.

In the case of performing the entire cavity for this hard material by the method of the present invention, it is possible to save the mechanical facilities, space, work, etc. to a considerable extent with the above effects, and even when using continuous plate rods as raw materials, automation is very easy. Is achieved.

As for the processing apparatus of the present invention, processing machinery for synthetic resins such as injection molding machinery can be effectively used.

That is, in the case of such apparatuses, there is a technique for complexly moving a template, a core, a pin, etc. in order to manufacture components made of a synthetic resin having a complicated shape, such a technique is useful in practicing the present invention.

However, since the conventional injection molding air cannot be completely replaced by the press machine in view of the molding movement speed, it is not accurate what the part of the processing of the hard material should be performed by the steps of the present invention, and the ability of the machine. It is desirable to make a decision based on judgment.

In particular, the processing air can also be used by providing an injection port of synthetic resin. Most preferable is to use a processing apparatus designed to have the moldability of a synthetic resin and the processability of hard materials, and to allow the press section to have an optimum performance. Such selection and design can be easily made by using conventional press processing technology and synthetic resin processing technology.

In the step of the present invention, there is no particular limitation as to when the processing of the hard material is performed, and therefore, the processing may be any one selected from the adhesion of the hard material, after mounting, curing, after curing, and opening of the mold. Can be done in time.

In carrying out the invention, it is natural to carry out processing using a material that has not been fully processed, but this is done initially.

In the most preferred and very often used embodiment, in the case of chassis produced by the outsert molding method, the bending of the side to bend, the shallow drawing to prevent deformation, the bending to join the synthetic resin, etc. Is performed using mold movement when tightening the mold.

In the press working of the substrate, since a considerable force is applied on the substrate, when machining a part of the substrate, such as bending, blanking, etc., it is desirable to sufficiently tighten the other parts and to perform constant processing after a certain time delay. As described above with regard to a technique for providing a time delay when moving a mold, conventional techniques for forming airflow can be used.

The process of processing a hard material and combining this material with other parts is carried out with the same apparatus, so that the steps are simplified, the accuracy is improved and also the product having a complicated shape can be easily manufactured, In addition to the press working, it can be applied to processing such as coulking.

In the following, various embodiments of the present invention will be described according to the accompanying drawings. However, these embodiments are shown for understanding the present invention, and therefore, the scope of the present invention is not limited.

In the mold structure diagram of the accompanying drawings, only the cross-sectional view necessary for understanding the present invention is shown, but the whole of the present invention can be easily understood from the following description and the shape of the product. In addition, the flow path of the resin leading to the cavity and the pins for discharging the product and the discharge pieces are omitted.

FIG. 1 shows one embodiment of bending a substrate when tightening a mold, and can be applied to manufacture of a chassis or the like.

1 (A) shows the excretion of the mold, (B) shows a perspective view of the product.

In the excretion of the mold of FIG. 1A, (1) and (2) both represent a template, (3) and (4) are cavities, (5) are hard plates, and (6) Are holes on this hard plate, and (7) and (7 ') are presses for bending the substrate. The press type may have a structure that can move independently of the template. When the synthetic resin is molded on the hard plate, the substrate is processed by bending as shown by (8) by the press mold, as indicated by the product of FIG. 1 (B), and at the same time, the synthetic resin is applied to (9). Is molded as indicated.

2 shows an embodiment of shallow drawing a part of a runner on a substrate, which is drawn when the mold is clamped. In FIG. 2, (A) shows the cross-sectional view along the line II of FIG. 2 (C) about excretion of the metal mold | die seen from the uniaxial surface.

In Fig. 2 (A), (1) and (2) are templates, (3) (3 '), (4) and (4') are synthetic resin cavities, and (5) are runner cavities, ( 6) denotes a substrate, and 7 and 7 'denote holes of the substrate. Moreover, FIG. 2 (B) shows the cross-sectional view along the II-II line | wire of FIG. (C) regarding the excretion of this metal mold seen from the other perpendicular | vertical to the said one axis.

In FIG. 2 (B), (8) shows a core for drawing. When a synthetic resin is formed on the hard plate in the excretion, a product as shown in Fig. 2C is obtained.

In the figure, reference numeral 9 denotes a substrate, reference numerals 10 and 10 'denote a synthetic resin agent, and reference numeral 11 denotes a runner.

As indicated by the traversal of the runner portion of the product shown in FIG. 2D, the substrate is processed by the core 8 for drawing in the runner and drawn as indicated by 12.

Further, only the protrusion of the core for drawing may be used as the movable mold, so that the substrate may be drawn after the mold is clamped. And similarly, the deformation | transformation process like this is possible also in the case of the metal mold | die mentioned later. Deformation of the substrate due to shrinkage of the runner is reduced to that drawing.

3 shows one embodiment of providing a nail for bonding a synthetic resin, which is made by the movement of a nail core. That is, in the excretion of the mold of FIG. 3 (A), (1) and (2) represent a template, (3) represents a movable core for nail in the template 2, and (4) represents a substrate. The core 3 is moved to the position of the dotted line 3 'in the fresh, thereby providing the nail 6 to the substrate 4 when the synthetic resin 5 is molded.

Fig. 3 (B) shows the appearance of the product, and Fig. 3 (C) shows the cross section of the product.

4 shows a first embodiment of cutting out a hard plate from a continuous plate.

In the excavation of the mold of FIG. 4 (A), (1) and (2) are templates, (3) and (3 ') are press molds for blanking the substrate, and (4) are nails on the template (2). The core for and (5) represents a substrate. The press 4 is moved up and down, and the template 2 is provided with a recessed portion to enable movement.

Fig. 4 (B) shows the appearance of the product, Fig. (C) shows the cross section of the product, and Fig. (D) shows the formation of the substrate behind after cutting the substrate. The molded object of this is shown.

(8) in FIG. 4 (C) shows the nail processed by the core for nails 4 on the board | substrate 5, and (9) in FIG. 4 (D) shows the press type ( 3) and 3 'represent one hole formed by cutting down by moving down from the substrate 5. It is also possible to provide a nail for joining by a core which does not move as indicated in this figure. And that's also possible with movable cores.

In particular, molding shrinkage can be reduced by performing this process while the resin is curing.

FIG. 5 shows an embodiment in which a material mass is processed into a substrate by a press and the resulting substrate is composited with a resin. In the mold excretion of Fig. 5 (A), (1) and (2) represent a template, (3) represents a cavity and press type, (4) represents a raw material, and (5) represents a cavity press cavity. 5 (B) shows a cross section of the product. In addition, (3 ') shows the position of the extrusion mold 3 which protrudes at the time of press. That is, the raw material 4 is pressed into the shape as indicated by 4 'in FIG. 5 (B), and then the press die is withdrawn to the position 3, after which the synthetic resin body 5 is in the cavity (3). Is formed.

Figure 6 shows one embodiment that provides for cutouts in the steps of the present invention.

In the mold excretion of Fig. 6 (A), (1) and (2) denote a template, (3) and (4) denote a press die, and (5) denotes a substrate. When pressing and forming a synthetic resin, a composite article having an outer shell as shown in Fig. 6 (B) is obtained using a mold. That is, (6) shows the notch made in the board | substrate 5, and (7) shows the synthetic resin body. Such cutouts can be installed at any stage of the present invention.

7 shows one embodiment of insert molding.

In the mold excretion of Fig. 7 (A), (1) and (2) is a template, (3) is a substrate, (4) and (5) is a cavity, and (6) is a press for bending the template (1). Type.

7 (B) shows a cross section of the product. That is, the substrate 3 is insert molded into the synthetic resin body by the cavities 4 and 5, and at the same time, the substrate 3 is bent as indicated by 3 '.

8 shows one embodiment where a portion of the mold is exchanged when combining the press and the parts.

FIG. 8 (A) shows the excretion of the mold during press, where (1) is a press die, (2) is a template, (3) is a substrate, and (5) is a press core. 8 (B) shows the excretion of the mold during molding, and (4) shows the molding mold. That is, at the beginning of the press, a nail as indicated by (6) is formed on the substrate 3 by the core 5.

Next, the press die 1 is replaced by the molding die 4, and the synthetic resin is molded into the cavity 7, whereby a product having an appearance as shown in Fig. 8C is obtained. This exchange is carried out by means of slides, rotations, etc.

In the above figure, the two sheet molds mainly appear like molds, but more complicated molds having a time delay or the like as in the case of conventional injection molding may be arbitrarily used to carry out the present invention. In addition, with regard to the material for the mold, when processing a hard material, it is necessary to have a hard one, whereas corrosion resistance is necessary for the cavity, and therefore, it is necessary to have both, but practically depending on the parts It is desirable to change the components or to make parts replaceable with large consumption.

Claims (1)

Hard materials characterized in that the processing of hard materials, molding of synthetic resins and their assembling are carried out using a processing machine equipped with a molding ability of a synthetic resin and a processing capability of a hard material at the same time and by a series of processing operations. Method for manufacturing composite parts for insert or out insert molding made of synthetic resin.

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