JP7105178B2 - Injection-molded body manufacturing apparatus and manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to an apparatus and method for manufacturing an injection-molded article to be attached to an automobile part, and a resin-molded article.

An injection-molded article in which a lens and a housing are integrally molded is known as an example of an injection-molded article attached to a door mirror of an automobile. In this injection molded product, two members made of two types of resin materials are integrated. A gap is likely to be formed at the joint between the door mirror and the injection molded body. When a gap is formed, the gap causes wind noise during driving, and light leaks from the joint between the door mirror and the injection molded body. occur. As a countermeasure against wind noise and light leakage, a countermeasure member such as a packing is pasted on the joint portion after completion of the injection molding on the surface of the lens of the injection molded body.

The structure and manufacturing method of an injection-molded body manufacturing apparatus and manufacturing method are disclosed in Patent Documents 1 and 2, and a turntable is rotated to simultaneously perform a plurality of processes on the turntable. Integrating members made of different materials is disclosed.

JP 2016-117221 A JP 2010-179511 A

However, in the injection molded body manufacturing apparatus and manufacturing method described in Patent Documents 1 and 2, although resin molding that integrates two members is possible, a member for countermeasures against wind noise and light leakage is not included in the manufacturing apparatus. cannot be installed.

Therefore, countermeasure members for preventing wind noise and light leakage, such as packing, are to be added later to the injection molded body in a separate process. If the countermeasure member is retrofitted after injection molding, there is a problem that the material cost and the number of assembling man-hours are required.

In addition, if an automatic assembly machine for automatically assembling the countermeasure member is used, investment is required, and even if automatic assembly is used, the number of man-hours increases due to retrofitting. Further, when the countermeasure member has a complicated shape, there is a problem that automatic assembly itself is difficult.

In addition, if the countermeasure member is assembled in a separate process after the secondary injection for joining the two members, intermediate inventory is generated. Furthermore, since the injection-molded body after the secondary injection is removed from the manufacturing apparatus, there is a risk that foreign matter may adhere due to static electricity, and there is a risk of product variation due to backlash during assembly and setting.

The object of the present invention is to injection-mold a desired member and a wind noise/light leak countermeasure member in the same mold, and to join the wind noise/light leak countermeasure member molded in the previous step to another member. An object of the present invention is to provide a manufacturing apparatus and manufacturing method for an injection-molded article, and a resin-molded article.

According to one aspect of the present invention, resin is injected into a mold to mold first, second and third members, and the third member is joined to the second member when molding the second member. A manufacturing apparatus for an injection molded body that performs a subsequent injection and a secondary injection that integrates the first member with the second member to which the third member is joined by injecting resin into a mold. . The apparatus for manufacturing an injection molded article comprises a reciprocally rotating turntable, first, second and third molds arranged on the turntable at predetermined intervals along the direction of rotation of the turntable, and the 4th, 5th and 6th molds that are opened and clamped with respect to the 1st, 2nd and 3rd molds, and the 1st, 2nd and 6th molds that inject resin into the clamped molds 3 executing first position control and second position control for the injection device and the turntable, and performing first injection control and second injection for the first, second and third injection devices and a control unit that performs control. Further, when the control unit executes the first position control, the first mold and the fourth mold face each other, the second mold and the fifth mold face each other, and When the turntable rotates to the first rotation position where the third mold and the sixth mold face each other, and the control unit executes the second position control, the first mold and the sixth mold are rotated. The turntable rotates to a second rotation position where the molds face each other, the second mold and the fourth mold face each other, and the third mold and the fifth mold face each other. do. Further, when the control section executes the first injection control following the first position control, the primary injection is performed by the first injection device, and the first injection is performed in the first and fourth molds. The first member and the third member are molded, the second injection is performed by the second injection device, and the third member is joined in the second and fifth molds to form the second member and the first member. The third member is integrated with the member, and the primary injection is performed by the third injection device, and the third member is molded and the third member is formed on the second member in the third and sixth molds. Joining is performed. Further, when the control section executes the second injection control following the second position control, the primary injection is performed by the first injection device, and the second and fourth molds are subjected to the first injection. The first member and the third member are molded, the first injection is performed by the second injection device, the second member is molded in the third and fifth molds, and the third member is molded into the second member. The second member and the first member are joined together, and the secondary injection is carried out by the third injection device, and the third member is joined in the first and sixth molds. are integrated.

In another aspect of the present invention, the first, second and third molds are arranged at intervals of 120° along the rotation direction of the turntable, and the first rotation position and the second rotation position is a position forming an angle of 120° with respect to the rotation center of the turntable.

Another aspect of the present invention is to mold the first, second and third members by injecting resin into a mold, and to join the third member to the second member when molding the second member. A method for manufacturing an injection molded body in which primary injection and secondary injection for integrating the first member and the second member to which the third member is joined by injecting resin into a mold are performed. be. A method for manufacturing an injection molded article includes a reciprocatingly rotating turntable, first, second and third molds arranged on the turntable at predetermined intervals along the direction of rotation of the turntable, and 4th, 5th and 6th molds that are opened and clamped with respect to the 1st, 2nd and 3rd molds, and the 1st, 2nd and 6th molds that inject resin into the clamped molds 3 executing first position control and second position control for the injection device and the turntable, and performing first injection control and second injection for the first, second and third injection devices and a controller for executing control. Further, when the control unit executes the first position control, the first mold and the fourth mold face each other, the second mold and the fifth mold face each other, and When the turntable rotates to the first rotation position where the third mold and the sixth mold face each other, and the control unit executes the second position control, the first mold and the sixth mold are rotated. The turntable rotates to a second rotation position where the molds face each other, the second mold and the fourth mold face each other, and the third mold and the fifth mold face each other. do. Further, when the control section executes the first injection control following the first position control, the primary injection is performed by the first injection device, and the first injection is performed in the first and fourth molds. The first member and the third member are molded, the second injection is performed by the second injection device, and the third member is joined in the second and fifth molds to form the second member and the first member. and the third injection device performs the primary injection, molding the second member and joining the third member to the second member in the third and sixth molds. and Further, when the control section executes the second injection control following the second position control, the primary injection is performed by the first injection device, and the second and fourth molds are subjected to the first injection. The first member and the third member are molded, the primary injection is performed by the second injection device, and the second member is molded and the third member is molded in the third and fifth molds. The second member and the first member are joined by joining the members, and the secondary injection is performed by the third injection device, and the third member is joined in the first and sixth molds. unify.

In another aspect of the present invention, the first, second and third molds are arranged at intervals of 120° along the rotation direction of the turntable and form an angle of 120° with respect to the rotation center of the turntable. The turntable is reciprocated between the first rotational position and the second rotational position that form

In another aspect of the present invention, the second member is injection-molded in the third and fifth molds or the third and sixth molds, and the third member is placed in the mold in advance. spliced.

In another aspect of the present invention, the first member and the third member are simultaneously injection-molded in the first and fourth molds or the second and fourth molds, and after the injection molding, the third member is The member is moved inside the third and fifth molds or the third and sixth molds, and the third member is arranged inside the third and fifth molds or the third and sixth molds. In this state, the second member is injection molded in the third and fifth molds or the third and sixth molds, and the third member is joined to the second member.

In another aspect of the present invention, the first member and the third member are injection molded in the same process using the same resin material in the same mold.

In another aspect of the present invention, the injection molded body includes a housing as the first member made of a non-translucent resin, a lens as the second member made of a translucent resin, and a non-translucent resin. a wind noise/light leakage countermeasure member as the third member made of a flexible resin, and the wind noise/light leakage countermeasure member is provided along the outer peripheral portion of the lens.

According to the present invention, in addition to integral molding of two members, it is possible to mold one member and a wind noise/light leakage countermeasure member in the same process using a single injection molded body manufacturing apparatus. That is, on the turntable, one member and the wind noise/light leakage countermeasure member can be injection molded in the same mold and in the same process. Furthermore, when another member is injection-molded with another mold in the same process, the wind noise/light leakage countermeasure member molded in the previous stage can be joined to the other member. Thereby, the molding time of the injection molded body can be shortened. Furthermore, the accuracy of injection molding can be improved. In addition, after the wind noise and light leak countermeasure members are molded, the mold is transferred to the lens mold by a robot, and the lens is molded and the wind noise and light leak countermeasure members are joined to the lens. It is possible to manufacture without any intermediate inventory. Furthermore, since the housing and the anti-wind noise/light leakage countermeasure members are injection molded in the same mold, the molding of the wind noise and light leakage countermeasure members is not carried out in a separate process, reducing the number of workers and man-hours. can be done. This makes it possible to reduce processing costs. In addition, since the wind noise/light leakage countermeasure member is joined to the lens in the same process as the lens molding in the lens molding die, it is possible to reduce variations in attachment of the wind noise/light leakage countermeasure member. As a result, it is possible to suppress variations in assembly of the injection-molded article (resin molded article) and improve the quality of the injection-molded article.

1 is a schematic diagram showing the configuration of an apparatus for manufacturing an injection-molded article of the present invention; FIG. FIG. 2 is a schematic diagram showing processing at each position after turning the turntable of the apparatus for manufacturing an injection molded body shown in FIG. 1 counterclockwise by 120°; FIG. 2 is a conceptual diagram showing the structure of an injection molding apparatus, which is an example of the apparatus for manufacturing the injection molded body shown in FIG. 1; FIG. 4 is a plan view showing the structure of an injection molded body manufactured by the injection molding apparatus shown in FIG. 3; It is a figure which shows the assembly procedure in the manufacturing method of the injection molding of this invention, (a) is an assembly procedure in a 1st rotation position, (b) is an assembly procedure in a 2nd rotation position. 6 is a conceptual diagram showing a state in which a molded body is transferred from a housing molding die to a lens molding die in the assembly procedure shown in FIG. 5, where (a) is the housing molding die and (b) is the lens molding die is a type. FIG. 2 is a conceptual diagram showing the arrangement position of each mold of the injection-molded article manufacturing apparatus shown in FIG. It is the arrangement position of 6 molds. (a), (b), and (c) are conceptual diagrams showing the injection molding process at the first rotation position. (a), (b), and (c) are conceptual diagrams showing the injection molding process at the second rotation position. 6 is a perspective view showing the structure of the surface side of the housing formed in the housing molding step in the method of manufacturing the injection molded body shown in FIG. 5; FIG. FIG. 11 is a perspective view showing the structure of the back side of the housing shown in FIG. 10; 6 is a perspective view showing the structure of the wind noise/light leakage countermeasure member formed in the housing molding step in the method of manufacturing the injection molded body shown in FIG. 5. FIG. 6 is a perspective view showing the structure of a joined body of a lens and a wind noise/light leakage countermeasure member formed in a lens molding step in the method for manufacturing an injection molded body shown in FIG. 5. FIG. 6 is a perspective view showing the structure of a lens-housing molded body formed in a secondary molding step in the method of manufacturing the injection molded body shown in FIG. 5; FIG. FIG. 15 is a perspective view showing the structure of the lens-housing molded body shown in FIG. 14 from which the housing and the anti-wind noise/light leakage countermeasure member are removed; 6 is a perspective view showing the structure of the assembly after the inner housing assembly step in the method of manufacturing the injection molded body shown in FIG. 5; FIG.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

The injection molding apparatus (injection molded article manufacturing apparatus) 30 of the present embodiment performs primary injection of injecting resin into a mold to mold the first member, the second member, and the third member, and The first member, the second member, and the third member molded by the primary injection are transferred to another mold, and the second member is joined to the third member by injecting resin into the mold. Secondary injection is performed to integrate the member and the first member. The first member and the second member are members made of the same resin material or different resin materials.

In the present embodiment, as an example of an injection-molded article, a lamp 1 attached to a door mirror of an automobile as shown in FIG. 4 is taken up. 2 and the lens 3 as an example of the second member, which is a constituent member of the lamp 1, will be described. That is, the injection molded body of this embodiment is the lamp 1 in which the housing 2 and the lens 3 are integrally molded. The housing 2 is made of non-translucent resin such as polycarbonate resin, and the lens 3 is made of translucent resin such as acrylic resin.

In the present embodiment, injection molding of the housing 2, the lens 3, or the wind noise/light leakage countermeasure member (third member) 17 using any of the molds of the injection molding apparatus 30 is called primary injection. Alternatively, the housing 2 and the lens 3 to which the wind noise/light leakage countermeasure member 17 is joined may be integrated with any mold of the injection molding device 30 to form an injection molded body (the lamp 1 shown in FIG. 4). is called secondary injection (secondary molding).

The wind noise/light leakage countermeasure member 17 is a resin-made member for preventing wind noise and light leakage generated during driving in the lamp 1 attached to the door mirror of the automobile. The wind noise/light leakage countermeasure member 17 is made of, for example, non-translucent resin such as elastomer or polycarbonate resin. In the present embodiment, a case where the wind noise/light leakage countermeasure member 17 is made of, for example, a preica-based resin will be described. That is, in this embodiment, the case where the housing 2 and the wind noise/light leakage countermeasure member 17 are molded from the same resin material will be described.

Next, the injection molding apparatus (injection molded product manufacturing apparatus) 30 of the present embodiment shown in FIGS. 1 and 2 will be described. The injection molding device 30 reciprocates between a first rotation position where injection molding is performed and a second rotation position where injection molding is performed and is located at a predetermined angle with respect to the first rotation position and the rotation center C. A rotating turntable 5 is provided. In this embodiment, a case where the predetermined angle is 120° will be described. That is, the first rotational position and the second rotational position form an angle of 120° with respect to the rotation center C of the turntable 5 .

Furthermore, the injection molding apparatus 30 includes a first mold 6, a second mold 7 and a third mold 8 arranged on the turntable 5 at predetermined intervals along the direction of rotation of the turntable 5. there is In the present embodiment, the first mold 6, the second mold 7 and the third mold 8 arranged at an angle of 120° to each other with respect to the rotation center C on the turntable 5 are provided. will be explained. That is, the first mold 6 , the second mold 7 and the third mold 8 are arranged on the turntable 5 at intervals of 120° along the rotation direction of the turntable 5 .

The injection molding apparatus 30 includes a fourth mold 9, a fifth mold 10 and a sixth mold for opening and closing the first mold 6, the second mold 7 and the third mold 8. A mold 11 is provided. In addition, the first injection device 12, the second injection device 13, and the third injection device 14 for injecting resin into the clamped mold, and the reciprocating rotation (turning) operation of the turntable 5, mold opening and mold clamping are performed. Therefore, the fourth mold 9, the fifth mold 10 and the sixth mold 11 are moved closer to or away from any one of the first mold 6, the second mold 7 and the third mold 8. and a control unit 16 for controlling the injection operation such as the operation to cause the injection device to be used, the resin to be used, and the timing of injection. The control unit 16 controls the turntable 5 to perform first position control and second position control, and further controls the first injection device 12, the second injection device 13, and the third injection device 12, for example. The device 14 is controlled to execute the first injection control or the second injection control.

Each of the first mold 6, the second mold 7 and the third mold 8 provided on the turntable 5 is a lower mold. Of these, the first mold 6 and the second mold 7 are molds for molding the housing 2, and are female molds on the side where the injection-molded housing 2 remains in the mold when the mold is opened. be. The third mold 8 is a mold for molding the lens 3, and is a male mold on the side where the injection-molded lens 3 is removed from the mold when the mold is opened.

On the other hand, above the turntable 5 are arranged corresponding to the stop positions of the first mold 6, the second mold 7 and the third mold 8, and the first mold 6 and the second mold A fourth mold 9 , a fifth mold 10 and a sixth mold 11 are provided as upper molds for the mold 7 and the third mold 8 . Each of the fourth mold 9, the fifth mold 10 and the sixth mold 11 moves up and down to clamp the first mold 6, the second mold 7 and the third mold 8. Open. That is, the fourth mold 9, the fifth mold 10 and the sixth mold 11 are provided so as to approach and separate from any one of the first mold 6, the second mold 7 and the third mold 8. It is

The fourth mold 9 is a mold for molding the wind noise/light leakage countermeasure member 17, and when the mold is opened, the injection-molded wind noise/light leakage countermeasure member 17 remains inside the mold. is the male form of The fifth mold 10 and the sixth mold 11 are molds for molding the lens 3 and bonding the wind noise/light leakage countermeasure member 17 to the lens 3. When the molds are opened, injection molding is performed. The molded lens 3 is the female mold on the side that remains in the mold. The fifth mold 10 and the sixth mold 11 are also molds in which secondary injection (secondary molding) is performed. It does not remain in the fifth mold 10 and the sixth mold 11.

In addition, as shown in FIG. 7, each of the first mold 6, the second mold 7, the third mold 8, the fourth mold 9, the fifth mold 10 and the sixth mold 11 has an injection mold. A cavity 18 is formed according to the shape of the molding to be molded.

Further, as shown in FIG. 3, in the injection molding device 30, the first injection device 12 is attached to the fourth mold 9, the second injection device 13 is attached to the fifth mold 10, and the sixth mold A third injection device 14 is attached to the mold 11, and is controlled by a control unit 16 to inject a required resin at a required timing. Specifically, the first injection device 12 performs primary injection for molding the housing 2 and the wind noise/light leakage prevention member 17 . The second injection device 13 and the third injection device 14 are used for primary injection for molding the lens 3 and bonding the wind noise/light leakage countermeasure member 17 to the lens 3, or the wind noise/light leakage countermeasure member 17. Either one of the secondary injections of injecting an integration resin (see FIG. 15) 4 for integrating the cemented lens 3 and housing 2 is performed.

In addition, in the injection molding apparatus 30 of the present embodiment, the first injection device 12 includes an injection cylinder 12a having an injection port 12b. The second injection device 13 has an injection cylinder 13a having an injection port 13b, and the third injection device 14 has an injection cylinder 14a having an injection port 14b.

Specifically, in the first injection device 12, the housing 2 and the wind noise/light leakage prevention member 17 are formed by primary injection. At that time, the same resin for molding the housing 2 and the wind noise/light leakage countermeasure member 17 is injected from the injection port 12b of the injection cylinder 12a. In the second injection device 13, when forming the lens 3 by primary injection, the resin for forming the lens 3 is injected from the injection port 13b of the injection cylinder 13a. On the other hand, when the lens 3 and the housing 2 to which the wind noise/light leakage countermeasure member 17 is joined are integrated with the secondary injection, the integration resin 4 is injected from the injection port 13b of the injection cylinder 13a. Similarly, when forming the lens 3 by primary injection, the third injection device 14 injects the resin for forming the lens 3 from the injection port 14b of the injection cylinder 14a. On the other hand, when the lens 3 and the housing 2 to which the wind noise/light leakage countermeasure member 17 is joined are integrated with the secondary injection, the integration resin 4 is injected from the injection port 14b of the injection cylinder 14a.

Further, in the injection molding apparatus 30, the movement control of the 120° reciprocating rotation of the turntable 5 (first position control, second position control), the fourth mold 9, the fifth mold 10, the sixth mold 11, control of approaching and separating from the lower mold when closing and opening the mold, and injection control of the first injection device 12, the second injection device 13, and the third injection device 14 (first injection control, second injection control, injection control) is executed by the control unit 16 shown in FIG.

Further, as shown in FIGS. 1 and 2, handling robots are arranged around the turntable 5 at appropriate intervals. For example, a first robot 19 and a second robot 20 are arranged at positions facing each other around the turntable 5, and carry in and take out objects to be processed (formed objects) from the molds.

Next, control executed by the control unit 16 of the injection molding apparatus 30 will be described.

When the control unit 16 executes the first position control, the first mold 6 and the fourth mold 9 face each other, the second mold 7 and the fifth mold 10 face each other, and the third mold The turntable 5 rotates to the first rotation position where the mold 8 and the sixth mold 11 face each other.

Further, when the control unit 16 executes the second position control, the first mold 6 and the sixth mold 11 face each other, the second mold 7 and the fourth mold 9 face each other, and The turntable 5 rotates to the second rotation position where the third mold 8 and the fifth mold 10 face each other.

Further, when the control unit 16 executes the first injection control following the first position control, the primary injection is performed by the first injection device 12, and the housings in the first mold 6 and the fourth mold 9 are 2 and a wind noise/light leakage countermeasure member 17 are molded. Further, secondary injection is performed by the second injection device 13, and in the second mold 7 and the fifth mold 10, the lens 3 and the housing 2 to which the wind noise/light leakage countermeasure member 17 is joined are integrated, In addition, primary injection is performed by the third injection device 14, and molding of the lens 3 and bonding of the wind noise/light leakage countermeasure member 17 to the lens 3 are performed in the third mold 8 and the sixth mold 11. .

Further, when the control unit 16 executes the second injection control following the second position control, primary injection is performed by the first injection device 12, and the housings are 2 and a wind noise/light leakage countermeasure member 17 are molded. Further, the primary injection is performed by the second injection device 13, and the molding of the lens 3 and the bonding of the wind noise/light leakage countermeasure member 17 to the lens 3 are performed in the third mold 8 and the fifth mold 10. In addition, secondary injection is performed by the third injection device 14, and the housing 2 and the lens 3 to which the wind noise/light leakage countermeasure member 17 is joined are integrated in the first mold 6 and the sixth mold 11. be.

That is, in the injection molding apparatus 30 of the present embodiment, the housing 2 and the wind noise/light leakage countermeasure member 17 are arranged in the first mold 6 and the fourth mold 6 at the first rotation position and the second rotation position of the turntable 5, respectively. In the mold 9 or the second mold 7 and the fourth mold 9, injection molding is performed by the same injection operation by the second injection device 13 or the third injection device 14 in the same process.

Further, the lens 3 is injection-molded in the third mold 8 and the fifth mold 10 or in the third mold 8 and the sixth mold 11, and is preliminarily molded inside the third mold 8 and the fifth mold 10 or The third mold 8 and the sixth mold 11 are joined with the wind noise/light leakage countermeasure member 17 .

Next, the lamp 1, which is an injection molded body shown in FIG. 4, will be described. The lamp 1 is an injection molded body molded by the injection molding apparatus 30 shown in FIGS. 1 to 3 of the present embodiment, and is a resin molded product integrally molded with two or more types of resin. The lamp 1 mainly includes a lens (second member) 3, a housing (first member) 2 having a hollow structure, and a sealing member (see FIG. 15) 15 such as a light bulb and a socket provided therein. Consists of The housing 2 and the lens 3 are made of different resins, and are integrated by an integration resin 4 shown in FIG. Further, as shown in FIG. 4, a wind noise/light leakage countermeasure member 17 for preventing wind noise and light leakage is provided along the outer peripheral portion of the lens 3 . More specifically, a member (third member) 17 for countering wind noise and light leakage is provided at the joint portion of the outer peripheral portion of the lens 3 with the housing 2 . The housing 2 is made of a non-translucent resin, the lens 3 is made of a translucent resin, and the wind noise/light leakage prevention member 17 is made of a non-translucent resin.

The wind noise/light leakage countermeasure member 17 may be formed over the entire outer peripheral portion of the lens 3, or may be formed in a portion of the outer peripheral portion. Further, when the lamp 1 is attached to the door mirror, it may be provided at the junction between the main body of the door mirror and the lens 3 so as not to be exposed to the outside.

Next, a method for manufacturing an injection molded article according to this embodiment will be described.

As shown in FIG. 7A, on the turntable 5, the first mold 6, the second mold 7 and the third mold 8 are arranged at an angle of 120° with respect to the center of rotation C shown in FIG. are placed at intervals of In other words, they are arranged at intervals of 120° along the rotation direction of the turntable 5 . On the other hand, above the turntable 5, as shown in FIG. Each of a mold 9, a fifth mold 10 and a sixth mold 11 is arranged.

A method for manufacturing an injection molded body will be described along the injection molding procedure shown in FIG. In the manufacturing procedure using FIGS. 5(a) and 5(b), the present embodiment will be described assuming that the process starts from step 1 shown in FIG. 5(a). However, it goes without saying that the operation of step 10 is performed before step 1 in actual manufacturing.

First, the first rotation position and the second rotation position where the turntable 5 stops when it reciprocates and performs desired operations in each mold will be described. The first rotation position and the second rotation position are positions in which the turntable 5 reciprocates (revolves) clockwise or counterclockwise and then stops, and the respective molds perform processing such as injection molding. There is a positional relationship that forms an angle of 120° with respect to the rotation center C of the turntable 5 . For example, the rotational position of the turntable 5 shown in FIG. 1 is the first rotational position. Processing such as injection molding is performed.

Further, a position where the turntable 5 is rotated counterclockwise or clockwise by 120° from the first rotation position is, for example, the second rotation position shown in FIG. At the second rotation position as well, desired injection molding or other processing is performed at each of the A1 location, B1 location, and C1 location.

First, the case where the turntable 5 is stopped (positioned) at the first rotation position will be described. When the turntable 5 is positioned at the first rotation position, the first mold 6 is connected to the fourth mold 9, and the second mold 7 is connected to the fifth mold 10, as shown in FIG. 8(a). In addition, the third mold 8 is arranged to face the sixth mold 11 respectively. Then, as shown in step 1 of FIG. 5(a), the fourth mold 9 and the fifth mold, which are the upper molds of the respective molds, are placed at the positions A1, B1, and C1 in the first rotation position. 10 and the sixth mold 11 are moved to perform mold clamping (state shown in FIG. 8(a)).

After mold clamping, the first injection control is executed in step 2 of FIG. 5(a). Specifically, at point A1 in the state (first rotation position) shown in FIG. The light leakage countermeasure member 17 is molded (housing molding, wind noise/light leakage countermeasure member molding). The injection for molding the housing 2 and the wind noise/light leakage prevention member 17 in step 2 is primary injection by the first injection device 12 . At that time, the resin for molding the housing 2 and the wind noise/light leakage prevention member 17 is injected from the injection port 12b of the injection cylinder 12a of the first injection device 12 shown in FIG. 10 and 11 show the structure of the housing 2 molded by primary injection. As shown in FIG. 10, the housing 2 has a hollow portion 2a for mounting parts. FIG. 12 shows the structure of the wind noise/light leakage countermeasure member 17 molded in the first mold 6 and the fourth mold 9 by the primary injection of the first injection device 12 . The wind noise/light leakage countermeasure member 17 has a shape along the outer periphery of the lens 3 as shown in FIG. In this way, at the A1 point in step 2 of FIG. 5A, the housing 2 and the wind noise/light leakage countermeasure member 17 are placed in the same mold (the first mold 6 and the fourth mold 9), and in the same mold. Injection molding with resin material. Preferably, the housing 2 and the wind noise/light leakage prevention member 17 are injection molded at the same time.

Further, in step 2, the third mold 8 and the sixth mold 11 are used to mold the lens 3, which is the second member shown in FIG. ). The injection for molding the lens 3 in step 2 is primary injection by the third injection device 14 . At that time, the resin for molding the lens 3 is injected from the injection port 14b of the injection cylinder 14a provided in the third injection device 14 . Further, after the lens 3 is molded, the wind noise/light leakage countermeasure member 17 is joined to the lens 3 . That is, in the preceding step 10 , the wind noise/light leakage countermeasure member 17 is moved by the first robot 19 to the inside of the third mold 8 and the sixth mold 11 in advance. By performing the primary injection by the third injection device 14, the lens 3 is molded and the wind noise/light leakage countermeasure member 17 is melted to prevent wind noise/light leakage on the outer periphery of the lens 3 as shown in FIG. The light leakage countermeasure member 17 is joined. The wind noise/light leakage prevention member 17 is made of the same resin material as the housing 2, but the lens 3 is made of a different resin material.

Further, in step 2, the second mold 7 and the fifth mold 10 are molded by primary injection at the B1 point in the first rotation position shown in FIG. Secondary injection is performed by the second injection device 13 for integrating the lens 3 and the housing 2 together. At that time, an integration resin (see FIG. 15) 4 for integrally molding the housing 2 and the lens 3 is injected from the injection port 13b of the injection cylinder 13a provided in the second injection device 13. As shown in FIG. At this time, the unifying resin 4 is injected to the abutting portion between the housing 2 and the lens 3 . FIG. 14 shows a molded body integrated by secondary injection (secondary molding). That is, the molded body shown in FIG. 14 is a molded body in which the lens 3 and the housing 2 are integrated via the integrating resin 4 shown in FIG.

In the series of operations performed by the injection molding apparatus 30, when the process 2 after the process 1 shown in FIG. The housing 2 and the lens 3 have not yet been molded because they have not undergone any process. Therefore, only in the process 2 after the process 1 of the first cycle, the integration resin 4 is injected from the second injection device 13 for integrating the housing 2 and the lens 3 (secondary injection, secondary molding) are not performed, and the formation of the lamp 1 shown in FIG. 4 is not performed.

Thus, the injection molding at the positions A1, B1, and C1 at the first rotation position of the turntable 5, that is, the first injection control by the control unit 16 is completed. If step 2 following step 1 shown in FIG. 5(a) is the second cycle or later of the series of operations, the lamp 1 is formed by secondary injection at B1 in step 2. FIG.

After the formation of the lamp 1 is completed, as shown in step 3 of FIG. Mold opening is performed by moving the mold 9, the fifth mold 10 and the sixth mold 11 (state shown in FIG. 8(b)).

After the mold is opened, in step 4 of FIG. 5(a), the inner housing is assembled at point A1 in the first rotation position of the turntable 5. As shown in FIG. Here, as shown in FIG. 16, the first robot 19 shown in FIG. 1 arranges an LED (light-emitting diode) or a socket with a light bulb as the sealing member 15 in the hollow portion 2a of the housing 2 (see FIG. 8 ( state of b)).

Further, at the B1 position in the first rotation position of the turntable 5, the finished product and the anti-wind noise/light leakage countermeasure members are taken out by the robot. 14 is removed from the second mold 7 as shown in FIG. 8(b) by the handling of the first robot 19 shown in FIG. 12 is removed from the fourth mold 9 by the handling 19, as shown in FIG. 8(b).

Next, the control unit 16 executes first position control in which the turntable 5 is turned 120° counterclockwise from the first rotation position and stopped at the second rotation position. That is, the turntable 5 is positioned at the second rotation position (state shown in FIG. 2). When the turntable 5 is positioned at the second rotation position, the first mold 6 becomes the sixth mold 11 and the second mold 7 becomes the fourth mold 9, as shown in FIG. 8(c). , and a third mold 8 are arranged to face a fifth mold 10, respectively.

After turning the turntable 5 by 120°, in step 5 of FIG. 5B, the wind noise/light leakage countermeasure member 17 is set by the robot at the B1 point in the second rotation position. Here, in step 4 at location B1 shown in FIG. 5A, the first robot 19 shown in FIG. 6(b), as shown in FIG. 8(c), it is transferred (placed) inside the third mold 8 (cavity 18 shown in FIG. 7(a)).

After the movement of the wind noise/light leakage countermeasure member 17, in step 6 of FIG. 9. The fifth mold 10 and the sixth mold 11 are lowered to perform mold clamping (state shown in FIG. 9(a)).

After mold clamping, in step 7 of FIG. 5B, the second injection control is performed by the control unit 16. FIG. Specifically, at the point A1 in the second rotational position of the turntable 5, the second mold 7 and the fourth mold 9 are used to rotate the housing 2 as the first member and the wind noise/light leakage as the third member. The countermeasure member 17 is molded (housing molding, wind noise/light leakage countermeasure member molding). The injection of the resin for molding the housing 2 and the wind noise/light leakage countermeasure member 17 at the A1 location in step 7 is the primary injection by the first injection device 12 . At that time, a resin for molding the housing 2 shown in FIGS. 10 and 11 is injected from the injection port 12b of the injection cylinder 12a of the first injection device 12, and further the wind noise/light leakage prevention member 17 shown in FIG. 12 is molded. Inject the resin to That is, at A1 in step 7, the housing 2 and the wind noise/light leakage countermeasure member 17 are injection molded in the same mold (the second mold 7 and the fourth mold 9) using the same resin material. . Preferably, the housing 2 and the wind noise/light leakage prevention member 17 are injection molded at the same time. Incidentally, as shown in FIG. 10, the housing 2 is a member having a hollow portion 2a for mounting parts.

Further, in the step 7, the lens shown in FIG. 13, which is the second member, is formed with the third mold 8 and the fifth mold 10 as shown in FIG. 3 is molded (lens molding). The injection for molding the lens 3 in this step 7 is the primary injection by the second injection device 13 . At that time, the resin for molding the lens 3 is injected from the injection port 13b of the injection cylinder 13a provided in the second injection device 13 . Further, after the lens 3 is molded, the wind noise/light leakage countermeasure member 17 is joined to the lens 3 . That is, in step 5, the wind noise and light leakage countermeasure member 17 is moved inside the third mold 8 by the first robot 19 in advance, so that the lens 3 is molded and the wind noise and light leakage are suppressed. A countermeasure member 17 can be joined. As shown in FIG. 13, for example, the wind noise/light leakage countermeasure member 17 is melted and the wind noise/light leakage countermeasure member 17 is joined to the outer peripheral portion of the lens 3 when the lens 3 is molded. The wind noise/light leakage prevention member 17 is made of the same resin material as the housing 2, but the lens 3 is made of a different resin material.

Also, the injection of the lens 3 in step 7 is the primary injection by the second injection device 13 . At that time, the resin for molding the lens 3 is injected from the injection port 13b of the injection cylinder 13a provided in the second injection device 13 .

Further, in step 7, at the point C1 in the second rotation position, as shown in FIG. Secondary injection (secondary molding) is performed by the third injection device 14 that integrates the . At that time, an integration resin (see FIG. 15) 4 for integrally molding the housing 2 and the lens 3 is injected from the injection port 14b of the injection cylinder 14a provided in the third injection device 14. As shown in FIG. Specifically, the unifying resin 4 is injected to the butted portion between the housing 2 and the lens 3 . A wind noise/light leakage countermeasure member 17 is joined to the outer peripheral portion of the lens 3 . The molded body shown in FIG. 14 is a molded body (lamp 1) integrated (secondary molding) by secondary injection, and the lens 3 and the housing 2 are integrated via the resin 4 for integration shown in FIG. has been made In the lamp 1 , a member 17 for preventing wind noise and light leakage is provided at the joint between the lens 3 and the housing 2 . This completes the manufacture of the lamp (injection molded body) 1 shown in FIG.

After completion of manufacturing the lamp 1, as shown in step 8 of FIG. The molds are opened by raising the fifth mold 10 and the sixth mold 11 (state shown in FIG. 9(b)).

After the mold is opened, in step 9 of FIG. 5(b), the inner housing is assembled at the A1 point in the second rotation position. Here, the sealing member 15 is moved into the second mold 7 by handling by the first robot 19 shown in FIG. 1, as shown in FIG. 9(b). Specifically, as shown in FIG. 16, a bulb-equipped socket, which is the sealing member 15, is arranged in the hollow portion 2a of the housing 2. As shown in FIG.

Further, in step 9, the finished product and the anti-wind noise/light leakage countermeasure member are taken out by the robot at the point C1 in the second rotation position. Here, by handling the first robot 19 shown in FIG. 1, the finished lamp 1 shown in FIG. 14 is removed from the first mold 6 as shown in FIG. 12 is removed from the fourth mold 9 by the handling 19, as shown in FIG. 9(b).

Next, the control unit 16 executes the second position control to rotate the turntable 5 clockwise by 120° from the second rotation position and stop it. That is, the turntable 5 is positioned at the first rotation position. When the turntable 5 is positioned at the first rotation position shown in FIG. 8 are arranged to face the sixth mold 11 respectively.

After turning the turntable 5, in step 10 shown in FIG. 5A, the wind noise/light leakage countermeasure member 17 is set by the robot at the point C1 in the first rotation position. Here, the first robot 19 shown in FIG. 1 takes out the wind noise/light leakage countermeasure member 17 from the fourth mold 9 shown in FIG. , is moved (placed) inside the third mold 8 (cavity 18 shown in FIG. 7(a)).

This completes the description of one cycle of operation for assembling the lamp 1 at the first and second rotational positions of the turntable 5 in the injection molding apparatus 30 of the present embodiment. In actual assembly, the above one cycle of operation by the injection molding apparatus 30 is repeated multiple times to assemble.

According to the injection molding apparatus 30 and the method for manufacturing an injection molded body of the present embodiment, one injection molding apparatus 30 can integrally mold two parts (in the present embodiment, the housing 2 and the lens 3). Therefore, it becomes possible to mold one member and the wind noise/light leakage countermeasure member in the same process. That is, when the housing 2 and the wind noise/light leakage prevention member 17 are injection-molded on the turntable 5 using the same mold in the same process, and the lens 3 is injection-molded using another mold in the same process, the lens 3 The wind noise/light leakage countermeasure member 17 molded in the preceding step can be joined to the . Thereby, the molding time of the lamp 1 can be shortened. Furthermore, the accuracy of injection molding in forming the lamp by the injection molding apparatus 30 can be improved.

For example, after the secondary injection (secondary molding) for integrally molding two members, if the assembly of the wind noise/light leakage countermeasure member 17 is performed in a separate process, the molded body after the secondary injection is Since the product is taken out of the mold once, there will be variations in the product due to backlash during assembly and setting. However, in the injection molding apparatus 30 of the present embodiment, when the lens 3 is molded in the lens molding step preceding the integral molding, the wind noise/light leakage countermeasure member 17 is also joined to the lens 3. Since the lens 3 and the housing 2 to which the wind noise/light leakage countermeasure member 17 is joined are integrally molded, the accuracy of injection molding when molding the lamp 1 can be improved.

Further, after the wind noise/light leakage countermeasure member 17 is molded, the mold is transferred to a lens molding mold by a robot, and the lens molding and the wind noise/light leakage countermeasure member 17 are joined to the lens 3. It can be manufactured without being taken out from the molding device 30, and intermediate inventory can be eliminated. When the wind noise/light leakage countermeasure member 17 is transferred to the lens molding die, the wind noise/light leakage countermeasure member 17 is arranged so as to match the directions of the lens 3 and the housing 2 respectively. As a result, when the wind noise/light leakage countermeasure member 17 is joined to the lens 3 by the lens molding die or when the lens 3 and the housing 2 are integrally molded, the wind noise/light leakage countermeasure member 17 or the lens 3 can be removed. Efficiency of injection molding can be improved because there is no need to change the orientation.

Furthermore, since the housing 2 and the wind noise/light leakage countermeasure member 17 are injection-molded in the same mold, the wind noise/light leakage countermeasure member 17 is not molded in a separate process, and the manpower and man-hours of the operator are reduced. can be reduced. This makes it possible to reduce processing costs.

In addition, in the mold for molding the lens 3, since the wind noise/light leakage countermeasure member 17 is joined to the lens 3 in the same process as the lens molding, the housing 2 and the wind noise/light leakage countermeasure member 17 are injection molded. Since the same mold is used, variations in mounting the wind noise/light leakage countermeasure member 17 can be reduced, and variations in mounting the lamp (injection molding, resin molding) 1 can also be suppressed. Thereby, the quality of the lamp 1 can be improved.

It goes without saying that the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist of the present invention. For example, in the above embodiment, the case where the mold opening and mold clamping of the mold (upper mold) are simultaneously performed by the control unit 16 has been described. and the sixth mold 11 may be controlled by the control unit 16 so as to perform mold opening and mold clamping separately from each other.

In the above-described embodiment, the case where the wind noise/light leakage countermeasure member 17 is removed by the robot after the mold is opened after the secondary injection has been described. It may be performed after the assembly process.

Also, either the first robot 19 or the second robot 20 may be capable of taking out the finished product or taking out or supplying the member 17 .

Further, in the above embodiment, the angle formed by the first rotational position and the second rotational position, and the arrangement intervals of the first mold 6, the second mold 7, and the third mold 8 (angle with respect to the rotation center C) is 120°, but these angles are not limited to 120° and may be angles other than 120°.

Also, in the above embodiment, each injection device has a single injection cylinder, but each injection device may have a plurality of injection cylinders. For example, if the first injection device 12 has two injection cylinders, by injecting different resins from each injection cylinder, two members made of different resin materials can be injected from one mold. It is possible to mold.

1 lamp (injection molding, resin molding)
2 housing (first member)
2a hollow portion 3 lens (second member)
4 Unifying resin 5 Turntable 6 First mold 7 Second mold 8 Third mold 9 Fourth mold 10 Fifth mold 11 Sixth mold 12 First injection device 12a Injection cylinder 12b Injection port 13 Second injection device 13a Ejection cylinder 13b Ejection port 14 Third injection device 14a Ejection cylinder 14b Ejection port 15 Sealing member 16 Control unit 17 Wind noise/light leakage countermeasure member (third member)
18 cavity 19 first robot 20 second robot 30 injection molding apparatus

Claims (8)

primary injection for injecting resin into a mold to mold first, second and third members, and joining the third member to the second member when molding the second member; A device for manufacturing an injection molded body that performs a secondary injection for integrating the first member and the second member to which the third member is joined by injecting resin into the
a turntable that reciprocates,
first, second and third molds arranged on the turntable at predetermined intervals along the direction of rotation of the turntable;
fourth, fifth and sixth molds that are opened and clamped with respect to the first, second and third molds;
first, second and third injection devices for injecting resin into the clamped mold;
Control for executing first position control and second position control for the turntable, and executing first injection control and second injection control for the first, second and third injection devices Department and
has
When the control unit executes the first position control, the first mold and the fourth mold face each other, the second mold and the fifth mold face each other, and the second mold and the fifth mold face each other. The turntable rotates to a first rotation position where the third mold and the sixth mold face each other,
When the control unit executes the second position control, the first mold and the sixth mold face each other, the second mold and the fourth mold face each other, and the second mold and the fourth mold face each other. The turntable rotates to a second rotation position where the third mold and the fifth mold face each other,
When the control unit executes the first injection control following the first position control, the primary injection is performed by the first injection device, and the first member is injected into the first and fourth molds. and the third member is molded, the second injection is performed by the second injection device, and the third member is joined in the second and fifth molds to form the second member and the first member are integrated, and the primary injection is performed by the third injection device, and the molding of the second member and the joining of the third member to the second member are performed in the third and sixth molds. is done and
When the control unit executes the second injection control subsequent to the second position control, the primary injection is performed by the first injection device, and the first member is injected into the second and fourth molds. and the third member is molded, the primary injection is performed by the second injection device, and the third member is molded and the third member is molded into the second member in the third and fifth molds. The second member and the first member to which the third member is joined are joined in the first and sixth molds by performing the secondary injection by the third injection device, and Manufacturing equipment for integrated injection molding. In the injection molded article manufacturing apparatus according to claim 1,
The first, second and third molds are arranged at intervals of 120° along the rotation direction of the turntable,
The apparatus for manufacturing an injection molded body, wherein the first rotational position and the second rotational position form an angle of 120° with respect to the center of rotation of the turntable. primary injection for injecting resin into a mold to mold first, second and third members, and joining the third member to the second member when molding the second member; A method for manufacturing an injection molded body by performing a secondary injection for integrating the first member and the second member to which the third member is joined by injecting a resin into the second member,
a reciprocally rotating turntable; first, second and third molds arranged on the turntable at predetermined intervals along the direction of rotation of the turntable; and the first, second and third molds. Fourth, fifth and sixth molds to be opened and clamped with respect to the molds, first, second and third injection devices for injecting resin into the clamped molds, and the turntable. a control unit that executes first position control and second position control for the first, second, and third injection devices, and executes first injection control and second injection control for the first, second, and third injection devices; Prepare a manufacturing apparatus for the injection molded body having
When the control unit executes the first position control, the first mold and the fourth mold face each other, the second mold and the fifth mold face each other, and the second mold and the fifth mold face each other. The turntable rotates to a first rotation position where the third mold and the sixth mold face each other,
When the control unit executes the second position control, the first mold and the sixth mold face each other, the second mold and the fourth mold face each other, and the second mold and the fourth mold face each other. The turntable rotates to a second rotation position where the third mold and the fifth mold face each other,
When the control unit executes the first injection control following the first position control, the primary injection is performed by the first injection device, and the first member is injected into the first and fourth molds. and the third member is molded, the second injection is performed by the second injection device, and the third member is joined in the second and fifth molds to form the second member and the first member are integrated, and the primary injection is performed by the third injection device, and the molding of the second member and the joining of the third member to the second member are performed in the third and sixth molds. do,
When the control unit executes the second injection control subsequent to the second position control, the primary injection is performed by the first injection device, and the first member is injected into the second and fourth molds. and the third member are molded, the primary injection is performed by the second injection device, and the second member is molded and the third member is molded into the second member in the third and fifth molds. and performing the secondary injection by the third injection device to integrate the second member and the first member to which the third member is joined in the first and sixth molds. A method for manufacturing an injection molded body. In the method for manufacturing an injection molded article according to claim 3,
The first, second and third molds are arranged at intervals of 120° along the rotation direction of the turntable,
A method for manufacturing an injection molded body, wherein the turntable is reciprocally moved between the first rotational position and the second rotational position forming an angle of 120° with respect to the center of rotation of the turntable. In the method for manufacturing an injection molded article according to claim 3,
The second member is injection molded in the third and fifth molds or the third and sixth molds, and is joined to the third member that has been placed in the mold in advance. Production method. In the method for manufacturing an injection molded article according to claim 3,
The first member and the third member are simultaneously injection molded in the first and fourth molds or the second and fourth molds, and after the injection molding, the third member is molded in the third and fifth molds. It is transferred to the inside of the mold or the third and sixth molds, and with the third member arranged inside the third and fifth molds or the third and sixth molds, the third and sixth molds A method of manufacturing an injection-molded body, comprising injection-molding the second member in a fifth mold or the third and sixth molds, and joining the third member to the second member. In the method for manufacturing an injection molded article according to claim 3, 4, 5 or 6,
A method of manufacturing an injection-molded body, wherein the first member and the third member are injection-molded in the same process and in the same mold using the same resin material. In the method for manufacturing an injection molded article according to claim 3keep,
The injection molded body is
a housing as the first member made of a non-translucent resin;
a lens as the second member made of translucent resin;
a wind noise/light leakage countermeasure member as the third member made of a non-translucent resin;
has
The wind noise/light leakage countermeasure member is provided along the outer peripheral portion of the lens,Manufacturing method of injection molding.

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