JP2000313030A - Method for producing synthetic resin molded article having hollow part and synthetic resin molded article produced thereby - Google Patents

Abstract

PROBLEM TO BE SOLVED: To stably ensure the suitable mutual fitted and pressurized state of a pair of split bodies when the split bodies are mutually brought to a fitted and contact state to produce a synthetic resin molded article having a hollow part, and to enhance productivity without bringing about the scaling-up of a molded article size. SOLUTION: A molding process for molding a pair of synthetic resin split bodies (a main body Sb and a separate plate Sp) one of which has the outermost groove part Ga surrounding the outside of a liquid pressure circuit Be provided to the fitting surface thereof, a fitting process for fitting both split bodies to each other in such a state that the split bodies are held in the mold used in the molding process, and a bonding process for filling the outermost groove part with an adhesive in the fitted state to bond both split bodies, are provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a synthetic resin molded article having a hollow portion by abutting a pair of synthetic resin divided bodies with each other and joining the divided bodies at the abutting portion. The present invention relates to a method and a synthetic resin molded article produced by the method.

[0002]

2. Description of the Related Art As is well known, an automobile equipped with an automatic transmission (automatic transmission: so-called AT) (so-called AT car) is provided with a complicated flow path (hydraulic circuit) for operating oil of a gear change mechanism. A gear change control is performed by introducing the control valve into a control valve having a valve body and controlling the flow rate of hydraulic oil and the like by the valve. The valve body of the control valve (control valve body) is extremely difficult to manufacture by general machining such as cutting, because a hydraulic circuit having a very complicated flow path is provided inside.
Conventionally, a light alloy such as aluminum (Al) is used as a material and manufactured by, for example, a die casting method which can ensure high accuracy and is suitable for mass production.

When such a valve body is manufactured by, for example, Al die-casting as described above, the valve body is usually provided with a case portion provided with at least a main portion of a hydraulic circuit and a lid-shaped separate plate portion combined with the case portion. , And each divided body is formed by die casting,
A finished product is obtained by combining the two and joining them together with, for example, a screw member or the like. The control valve body thus obtained has a flow path (hydraulic circuit) forming a hollow portion inside. In this case, a gasket is interposed between the two divided bodies in order to prevent leakage of hydraulic oil between the internal flow paths and the outside, but in order to ensure a required sealing effect by the gasket, It is necessary to pay special attention to the surface properties such as sufficient polishing of the bonding surface of the divided body.

[0004] With the recent demand for improved fuel efficiency of automobiles, further reduction in the weight of accessories around the transmission has been required, and the control valve body is relatively large. So the conventional A
It has been considered to use a synthetic resin instead of a light alloy such as a 1 alloy. In the case of a control valve, it is a component of a power transmission system whose operating temperature condition is lower than that of an engine system or the like, and a synthetic resin (particularly, a synthetic resin reinforced with fibers or the like) can be sufficiently applied. .

When a structure having a hollow portion, such as the above-mentioned control valve body, is made of synthetic resin, similarly to the case of the die casting method, it is divided into a case portion and a separate plate portion, and each divided body is synthesized. A general method may be considered in which a resin is formed in advance, the divided bodies forming the pair are abutted, and an adhesive is applied to the abutted surface. However, high-pressure working fluid flows inside like the control valve body,
In the case where reliable liquid tightness between the internal flow paths and the outside is required, the bonding portion is required to have high bonding strength and reliability against leakage.

[0006] In this regard, although not having a hollow body in mind, for example, Japanese Utility Model Laid-Open No. 3-504.
Japanese Patent Application Laid-Open No. 19-1992 discloses that when synthetic resin members are joined with an adhesive, an adhesive flow path (a groove for pouring the adhesive) is formed in a joint surface of one of the two members separately formed in advance. ) Is provided, and in a state where the joining surfaces of both members are abutted against each other and pressurized, an adhesive is injected from an injection port provided in the other member, so that the adhesive is poured into the groove and both members are It has been proposed to join.
According to this method, the adhesive can be injected into the bonding portion (groove for the adhesive) without waste, and the reliability of bonding can be increased.

[0007]

However, when the control valve body has a complicated flow path (flow path for flowing hydraulic oil) inside like the above-described control valve body, the groove for the adhesive is formed by the hydraulic oil. Since it is provided to avoid interference with the flow path, it must be extremely complicated, and together with the complexity of the outer shape itself, the divided bodies (the case part and the separate plate part) are impinged on each other. At the time of joining, there is a problem that it is difficult to stably obtain a suitable abutment and pressurized state such as securing the positioning accuracy and securing a uniform pressing force.

For example, when manufacturing a control valve body of an AT for a mass-produced vehicle, a method having a higher production efficiency is required. However, conventionally, the molding of each divided body and the joining of the two are performed in separate steps. Therefore, there is a problem that it takes time to transfer and set each divided body to the forming itself and the joining step, and it is generally difficult to further improve the productivity.

By the way, as a method of manufacturing a synthetic resin molded body having a hollow portion, split portions made of synthetic resin are brought into abutment with each other, and an inner passage formed in the abutment portion or a mold wall is interposed between the divided portions. A method of obtaining a hollow molded product by joining the divided bodies by filling the formed passage with a molten resin is known. In addition, a method is known in which, when the divided bodies are joined in this way, the passage is filled with a molten resin in a mold for molding the divided bodies. By adopting such a method,
When abutting the divided bodies, it is possible to stably obtain a suitable abutment and pressurized state, such as securing the positioning accuracy and securing a uniform pressing force. It is possible to more stably secure the joint strength between the members and the sealing property of the abutting portion.

For example, Japanese Patent Publication No. 2-38377 basically provides a male mold part and a female mold part for molding a set of divided bodies in one mold, and the other mold. Discloses a pair of mold structures provided with a female mold portion and a male mold portion facing these mold portions, and by using such a mold, each divided body is simultaneously molded ( After the injection molding, one of the molds is slid with respect to the other to abut the divided bodies left in the respective female mold parts, and the molten resin (2) is inserted into the internal passage of the abutment part. (So-called die slide injection (DSI))
Law) is disclosed. According to the DSI method, the productivity can be greatly improved as compared with the conventional method in which the forming of the divided body and the abutment / joining are performed in completely different steps.

Japanese Patent Publication No. 7-4830 discloses a molding die which can be opened and closed with each other, and one of the molding dies can be used to improve the production efficiency. The mold can be rotated by a predetermined angle, and each mold has a male / female /
At least one male molding and 2
There is disclosed a mold structure for rotary injection molding provided with a molding part composed of two female mold parts, and by using such a molding die, each divided body is molded at every rotation (for example, forward / reverse) operation. And a rotary injection molding method (so-called die rotary injection (DRI) method) in which a pair of abutted divided bodies are joined to each other to obtain a finished product for each rotation operation. I have.

As described above, the DRI method or the DSI
It is possible to stably obtain high productivity and quality by using the DRI method.
In the method I, the molten resin (secondary resin) is filled in the internal passage of the abutting portion and the two divided bodies are joined to each other, and the molten resin is uniformly spread over the entire length of the narrow internal passage. ,
A fairly high filling pressure is required for reliable bonding. In particular, when the present invention is applied to a control valve body having a complicated hollow portion (flow path portion for flowing hydraulic oil) inside as in the above-described control valve body, the internal passage for the secondary resin is also extremely complicated. Therefore, it is more difficult to uniformly fill the molten resin, and it is necessary to further increase the filling pressure. For this reason, the wall part forming the internal passage must be set to a relatively large thickness (for example, about 6 mm or more), and there is a problem that the entire size becomes too large.

The present invention has been made in view of the above-mentioned problems, and when a pair of divided bodies are joined and joined to each other to produce a synthetic resin molded body having a hollow portion, the divided bodies are not joined to each other. The basic purpose is to stably secure a suitable abutment and pressurized state, and to improve the productivity without increasing the size of the compact such as an increase in wall thickness. is there.

[0014]

For this reason, the invention according to claim 1 of the present application (hereinafter referred to as the first invention) has a pair of synthetic resin divided bodies abutted to each other, and the abutting portion makes the two abutted parts. Assuming a manufacturing method for manufacturing a synthetic resin molded body having a hollow portion by joining divided bodies, at least one of the abutting surfaces is provided with at least one groove having a groove surrounding the outside of the hollow portion. A molding step of molding the resin divided body, an abutting step of abutting the two divided bodies with each other while holding the respective divided bodies in the mold used in the molding step, and the groove portion in this abutted state And a bonding step of filling the two divided bodies with each other by filling an adhesive.

Further, the invention according to claim 2 of the present application (hereinafter referred to as “the invention”)
In the first invention, the molding die is a fixed die having at least a female molding part for molding the first divided body and a male molding part for molding the second divided body. A movable die having at least a male molded part for molding the first divided body and a female molded part for molding the second divided body, wherein the movable mold and the fixed mold are openable and closable with each other and at least one of One is provided so as to be relatively movable with respect to the other, and by clamping the movable mold and the fixed mold,
The first divided body forming cavity formed by the female molded part and the male molded part for forming the first divided body, and the second division formed by the male molded part and the female molded part for forming the second divided body After forming the body molding cavity, the first and second divided bodies are molded by injecting the molten resin into the first and second molding cavities in the molding step, and after the molding step, the movable mold is formed. The mold is opened with the fixed mold, and at least one of the two molds is relatively moved with respect to the other while holding the divided bodies corresponding to the respective female mold parts, and then both molds are again moved. The first and second divided bodies are brought into abutment with each other by clamping, and in this abutted state, an adhesive is press-fitted from an injection port communicating with the groove and filled in the groove, thereby forming the two parts. It is characterized in that the divided bodies are bonded together.

Further, the invention according to claim 3 of the present application (hereinafter referred to as “the invention”)
According to a third aspect of the present invention, in the second aspect, the movable mold and the fixed mold are configured such that one of the movable molds and the fixed mold is rotatable at a predetermined angle with respect to the other, and each of the molding dies is rotated in the rotation direction at the predetermined angle. It is for rotary injection molding provided with at least one male molding part and two female molding parts in the order of repetition of male / female / female. And a pair of divided bodies joined to each other are joined to obtain a finished product for each rotation operation.

Further, the invention according to claim 4 of the present application.
(Hereinafter, referred to as a fourth invention) is a synthetic resin molded body having a hollow portion produced by abutting a pair of synthetic resin divided bodies with each other and joining the divided bodies together at the abutting portion. In addition, it is manufactured by the manufacturing method according to any one of claims 1 to 3.

Further, the invention according to claim 5 of the present application.
According to a fifth aspect of the present invention, in the fourth aspect, the synthetic resin molded body is a control valve body having a hydraulic circuit therein.

Further, the invention according to claim 6 of the present application is further provided.
(Hereinafter referred to as a sixth invention) In the fifth invention, the control valve body includes a main body having a hydraulic circuit formed therein and a separate plate joined to the main body by abutment with the main body. A groove for adhesive surrounding the outside of the hydraulic circuit and a groove for adhesive corresponding to a partition of the main body forming the hydraulic circuit are provided on the abutting surface of the separate body. It is characterized by.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the present invention will be described below with reference to a valve body of a control valve of an automatic transmission (automatic transmission: so-called AT) for a vehicle. This will be described in detail with reference to the accompanying drawings, taking as an example the case where the present invention is applied to the manufacture thereof. FIG. 14 is an explanatory plan view showing a main body of a control valve body according to the present embodiment and a hydraulic circuit thereof. FIG. 15 is a view showing a state in which a separate plate is combined with the main body.
It is a longitudinal section explanatory view along the line. Further, FIG. 16 is an enlarged vertical sectional view of a portion Y16 in FIG. 15 showing an enlarged view of a joint portion between the main body and the separate plate.

As shown in these figures, the control valve body Sa is basically a main body provided with a complicated flow passage Bc (hydraulic circuit) on one side for flowing hydraulic oil of a gear change mechanism. Sb, and a substantially flat separate plate Sp that is combined with the main body Sb on the side where the hydraulic circuit Bc is formed. The main body Sb and the separate plate Sp are both made of synthetic resin, and are brought into contact with each other, and the two divided bodies are joined to each other at the abutting portion.
The control valve body Sa having the letter c is formed.

In the present embodiment, the main body Sb
A groove G (adhesive groove) is formed on an abutting surface of at least one of the separate plate Sp (in the present embodiment, more preferably, on the side of the separate plate Sp). The groove portion G includes a groove portion Ga surrounding the outside of the hydraulic circuit Bc (that is, an outermost groove portion) and a groove portion Gw corresponding to each partition Bw forming the hydraulic circuit Bc. As described, the main body S
b and the separate plate Sp are abutted, and the adhesive groove G (Ga + Gw) is filled with a predetermined adhesive so that the two Sb and Sp are joined by bonding. Note that the main body Sb and the separate plate Sp are the “pair of synthetic resin divided bodies” described in the claims of the present application.
In addition, the control valve body, the hydraulic circuit Bc thereof, and the outermost adhesive groove Ga are respectively referred to as the “synthetic resin molded product” and the “hollow portion” and “hollow portion” of the present invention. The groove surrounding the outside of the "."

In the example shown in FIGS. 14 to 16, the adhesive groove G (Ga + Gw) is formed by the separate plate Sp.
The peripheral shape of the longitudinal section is formed in a U-shape that is open to the abutment surface side. Specifically, dimensions are set (unit: millimeter [mm]) as shown in FIG. However, as for the cross-sectional shape and dimension setting of the adhesive groove, various other forms are conceivable, for example, as shown in FIGS. In the specific examples of FIGS. 18 to 20, the adhesive groove portions G2 to G4 have different peripheral shapes in the vertical cross section, respectively, but all of them have the tip portions (outermost adhesive groove portions) of the partition walls Bw2 to Bw4 of the main bodies Sb2 to Sb4. In the case of, the outer peripheral wall portion) and the separate plates Sp2 to S
The groove is formed on the abutment surface of p4 and the two are combined to form the adhesive groove portions G2 to G4.

Further, in the specific example shown in FIG.
w5 is composed of a first partition wall W1 on the main body Sb5 side and a second partition wall W2 on the separate plate Sp5 side. Grooves are formed in the respective tip portions of the first and second partition walls W1 and W2, and both the W1 and W2
, The partition Bw5 is formed, and an adhesive groove G5 is formed therein. In this case, since the adhesive groove G5 is formed inside the partition wall Bw5, it is necessary to set the groove width smaller than that of the specific examples shown in FIGS.

FIG. 22 shows an example of setting the groove shape and dimensions when it is assumed that bonding is performed with a molten resin in the DRI method or the DSI method. In this case, the partition Bw 'is formed by abutting the first partition W1' on the main body Sb 'side and the second partition W2' on the separate plate Sp 'side, and a molten resin However, since the flowability of the molten resin is low (compared with the adhesive) and a high filling pressure (typically about 400 kgf / cm ² ) is required, the cross-sectional area of the groove G ′ is reduced. It is necessary to secure a large wall thickness.
m), it must be set to be much thicker (to 6 mm).

The main body Sb and the separate plate Sp are more preferably formed by a so-called DRI method, and abutment and adhesion are performed using the forming die. Hereinafter, a method for molding the main body Sb and the separate plate Sp and a method for joining the two Sb and Sp, that is, a method for producing the control valve body Sa which is a synthetic resin molded body according to the embodiment of the present invention will be described. Prior to the description of a specific example of DRI molding of this synthetic resin molded body (control valve body),
First, the basic concept of the DRI molding method will be described.

FIG. 1 is a conceptual diagram of a combination of a fixed die 1 and a movable die 2 of a DRI molding die for explaining the basic concept of the DRI molding method, and FIG. FIGS. 3 (a) and 3 (b) show FIGS. 1 (a) and 1 (b) in a state where the molding dies (fixed die 1 and movable die 2) shown in FIG.
2 is a sectional view taken along line AA and a sectional view taken along line BB of FIG. As shown in these figures, the DRI mold is basically configured by combining a fixed mold 1 and a movable mold 2 and a movable mold 2.
Are opened and closed with respect to the fixed mold 1 at a predetermined timing.

As shown in FIG. 12 (a), the fixed mold 1 has a female-male combined male mold that forms a left half 31 when a hollow molded product W is divided into two parts, left and right. Molding part 11
And a female mold forming part 12 for male-female mold formation forming the right half 32 and a female forming a butting abutting part 33 with the right half 32 while holding the left half 31. One of the female mold forming parts 13 of the female mold matching is n = 1 in 360 / 3n.
In other words, the repetition order of male-female-female is once, and
It is arranged every 20 degrees. These molded parts 11 to 13
Is connected to a sprue 14 located at the center of the fixed mold 1, and a nozzle hole of an injection nozzle (not shown) of an injection molding machine communicates with the sprue 14. The molten material resin injected from the injection nozzle is supplied to the molding portions 11 to 13 via the sprue 14 and the common runner 15 extending radially in order.

On the other hand, the movable mold 2 has a female-male combined female mold portion 21 forming a left half body 31 corresponding to the fixed mold 1 and a male half forming a right half body 32. A male mold forming part 22 for female matching, and the other female forming part 23 for female-female matching forming a butting butting part 33 with the right half 32 while holding the left half 31; Are provided every 120 degrees. Each of the molded portions 21 to 23 is a fixed-side runner 1 extending radially from a sprue 14 located at a central portion on the fixed side.
The material resin is supplied by a common runner 25 extending in correspondence with 5.

Although not specifically shown, the movable mold 2 is provided with a rotation mechanism for rotating the movable mold 2. As the rotation mechanism, various structures can be applied.For example, arc-shaped rack teeth provided on the outer periphery of the movable die, a pinion gear meshing with the rack teeth, and a rotational drive of the pinion gear And a driving source (for example, a hydraulic motor or the like) for performing
With the rotation of the pinion gear (that is, according to the rotation direction and the number of rotations of the pinion gear), the movable mold 2 is rotated by a predetermined angle in a predetermined direction. The control of the rotation of the pinion gear (i.e., the control of the rotation of the rotor) is performed by controlling the operation of a drive source such as a hydraulic motor. The rack tooth portion is provided over an arc length corresponding to an angle of at least 120 degrees,
The movable mold 2 is set so as to be alternately rotated in a forward direction and a reverse direction by 120 degrees at a predetermined timing.

Incidentally, in the example shown in FIGS.
In addition, the molding parts are arranged on the mold surface of the movable mold 2 at every 120 degrees, and the rotation is performed at every 120 degrees.
As shown in (b) and (b), the fixed type 1 ′ has male 11-female 12
-The female 13 and male 11'-female 12'-female 13 'type arrangement are repeated, and the movable type 2' corresponds to the fixed type 1 '
-Even if the mold arrangement of male 22-female 23 and female 21'-male 22'-female 23 'is repeated, six molds are arranged every 60 degrees, and the mold plate is rotated back and forth by 60 degrees. Good. This allows two hollow bodies to be formed at a time with a small rotation angle.

The arrangement angle of the mold is the same as that of FIG. 1, but as shown in FIGS.
The common runner portion 2a may be fixed and the mold portion 2b may be rotated. In this case, it is preferable that the fixed mold 1 is not provided with a runner and the movable mold 2 is formed with a runner groove exclusively. In this configuration, the gate cut can be automatically performed by rotating only the peripheral mold portion 2b, and the "saw meat" corresponding to the sprue / runner can be eliminated. 4 (a) and 4 (b) and FIG. 5 (a)
In the descriptions of (b) and (b), the same components as those in FIGS. 1 to 3 are denoted by the same reference numerals, and further description is omitted.

The outline of rotary injection molding (DRI molding) performed using the mold shown in FIGS. 1 to 3 will be described in the order of the steps. FIGS. 3A and 3B are cross-sectional views taken along lines AA and BB of FIG. 1 in a state where the fixed mold 1 and the movable mold 2 shown in FIG. However, as shown in these figures, the fixed mold 1 and the movable mold 2 have, in their initial state, a male molded part 11 and a female molded part 21, and a female molded part 12 and a male molded part 22. The female mold 13 and the female mold 23 are combined so as to form a cavity (space).

In the first shot, as shown in FIG. 6, a dummy product D is inserted into a cavity formed by the female mold portion 13 and the female mold portion 23, and the molten material resin is injected. The injection is performed as shown in FIG. This allows
A left half body 31 is formed in the molding cavity (molding space) of the male mold part 11 / female mold part 21, and a right half body 32 is formed in the mold cavity of the female mold part 12 / male mold part 22, Each is molded. Further, a portion C corresponding to the abutting portion is formed on the dummy product D. When the mold is opened from this state, the left half body 31 remains in the female mold section 21 and the female mold section 12
The right half body 32 remains, and the mold is separated from the female molded part 13-the female molded part 23 in such a manner that the abutting part C is attached to the dummy product D (see FIG. 8).

Next, as shown in FIG. 9, when the movable mold 2 is rotated clockwise by 120 degrees and the mold is set, as shown in FIG. 31 and the right half body 32 of the female molding 12 are abutted. Further, a cavity (see FIG. 10A) for molding the left half body 31 with the male mold part 11 and the female mold part 23 is provided.
The female mold part 13 and the male mold part 22 form cavities (see FIG. 10 (b)) for molding the right half 32, respectively. In this state, when the material resin is supplied from the spool 14 via the common runner 15, as shown in FIG. 11, the left half body 31 of the female mold 21 and the female mold 1
2 is formed at the abutment portion 33 with the right half 32, and the left half 31 is formed in the molding cavity of the male mold 11 / female mold 23, and the female mold 13 / The right half body 32 is molded in the molding cavity of the male mold part 22. When the mold is opened from this state, the left half body 31 is left in the female mold part 23 and the right half body 32 is left in the female mold part 13, and the female mold part 21 / the female mold part 12 is left. The mold is released from the cavity in such a manner that the abutment portion 33 is attached to the left and right hollow body product W (see FIG. 12).

Then, as shown in FIG. 13, the movable mold 2 is reversed in the counterclockwise direction by 120 degrees to return to the original state.
When the molds are matched, the left half body 31 of the female mold part 23 and the right half body 32 of the female mold part 13 abut against each other.
That is, in this state, the dummy product D in FIG. 5 is merely changed into an abutting body of the left half body 31 and the right half body 32, and the description is omitted. By repeating the above operation, one abutted molded product (hollow body product) W is sequentially molded in one shot (one injection). The amount of resin required for one injection molding is determined by the left and right half-pieces 3.
1, 32, the abutment portion 33, and the so-called “saw meat” portion corresponding to the common runner, which is the same for each shot.

Next, a DRI mold used for manufacturing the control valve Sa, which is a synthetic resin molded body according to the embodiment of the present invention, will be described. FIG. 23 and FIG.
FIG. 4 is a vertical cross-sectional explanatory view showing cross-sections of the DRI mold according to the present embodiment, which are different from each other and show a matching state. FIG. 25 to FIG. 27 are longitudinal sectional explanatory views showing, on an enlarged scale, cavity portions obtained in the mold matching state. Further, FIGS. 28 and 29 are schematic explanatory diagrams showing the cavity position on the mold mating surface of the above-mentioned mold for different rotor rotation states. Note that FIG.
FIG. 24 is an explanatory longitudinal sectional view taken along the line Yb-Yp in FIG. 29, and FIG. 24 is a sectional view taken along the line Ya-Y in FIGS.
It is a longitudinal section explanatory view along the p line.

As can be clearly understood from FIGS. 23 and 24,
The fixed die 50 of the molding die has a base plate 51 forming a base of the fixed die 50 and a predetermined angle (1
(20 degrees) and a rotatable rotor 52 are configured as main parts. In this embodiment, the above-described FIGS.
Unlike the case of the conceptual description shown in FIG. 3, the fixed type side (that is, the rotor 52) rotates. A sprue bush 41 is fixed to the center of the base board 51, and the rotor 52 is rotatably supported by the sprue bush 41. An injection nozzle (not shown) of a molding machine for injecting and supplying a molten resin into the molding die is connected to the sprue bush 41. Sprue bush 4
1 has a sprue portion 42 having one end communicating with the nozzle hole of the injection nozzle and the other end communicating with the common runner 45.
Are formed.

The fixed die 50 is provided with a rotor rotating mechanism for rotating the rotor 52. The rotor rotation mechanism includes, for example, an arc-shaped rack tooth 52g provided on the outer periphery of the rotor, a pinion gear 56 that meshes with the rack tooth 52g, and a drive source (for example, a rotary drive for rotating the pinion gear 56). A hydraulic motor 55 etc.) as a basic component, and rotates the rotor 52 in a predetermined direction at a predetermined angle with the rotation of the pinion gear 56 (that is, according to the rotation direction and the number of rotations of the pinion gear 56). Only to rotate. The control of the rotation of the pinion gear 56 (that is, the control of the rotation of the rotor 52)
This is performed by controlling the operation of a drive source such as the hydraulic motor 55.

In this embodiment, the rack teeth 52g
Is provided over an arc length corresponding to an angle of at least 120 degrees, and the rotor 52 is set so as to be alternately rotated in a forward direction and a reverse direction by 120 degrees at a predetermined timing. At this time, a rotational sliding operation is performed between the rotor 52 and the base board 51 on the surfaces facing each other. Incidentally, the rotor rotation mechanism is not limited to the above example, but may be of various other configurations using various conventionally known mechanisms and mechanical elements to conform to the structure and characteristics of the molding die. Can be applied. On the other hand, the movable mold 70 includes a base board 71 forming a base of the movable mold 70 and a mold board 72 integrally fixed to the base board 71. The three molding portions on the movable mold side are formed on the mold plate 72. The mechanism for opening and closing the movable mold 70 with respect to the fixed mold 50 is the same as a conventionally well-known mechanism, so that illustration and description thereof are omitted.

An ejector mechanism for driving an ejector pin on the movable mold side is provided on the back side of the base board 71. Although not specifically shown, the ejector mechanism includes an ejector board fixed to the base board 71, and a drive pin disposed between the ejector board and the mold board 72 so as to move forward and backward. When the drive pins are moved forward and backward by a drive cylinder provided on the back side of the ejector substrate, each ejector pin comes and goes from the surface of the mold plate 72 at a predetermined timing to perform an ejector operation. ing. Although not specifically shown, the fixed die 50 is also provided with an ejector pin supported by an ejector plate. For example, by driving the ejector plate with a driving cylinder, the ejector pin is set at a predetermined timing. To move forward and backward.

On the mold surface of the rotor 52 of the fixed mold 50,
One male molded part 52 # and two female molded parts 52F in the rotating direction of male / female / female in the rotation direction every 120 degrees.
1 and 52F2, while the mold plate 7 of the movable mold 70 is provided.
The second mold surface is also provided with one male mold part 72 # and two female mold parts 72F1 and 72F2 in the same male / female / female repetition order in the rotation direction every 120 degrees.
Then, in a predetermined rotor rotation state, the fixed die 5
By closing the movable mold 70 with respect to the mold 0 and clamping the movable mold 70 with respect to the mold cavity, for example, FIGS.
The initial state shown in FIG. 8 is obtained.

That is, in this rotor rotating state (initial state), the movable mold 70 is closed with respect to the fixed mold 50, as shown in detail in FIGS. The combination of the molding part 52 # and the female mold part 72F1 on the movable mold 70 side makes the molding cavity Cb of the main body Sb the female mold part 52F on the fixed mold 50 side.
1 and the male mold forming part 72 # on the movable mold 70 side, the molding cavity Cp of the separate plate Sp, and the female mold forming part 52F2 on the fixed mold 50 side and the female mold forming part 72F2 on the movable mold 70 side. An abutment cavity Ca for combining and abutting both parts in combination is formed in a circumferentially equidistant shape (that is, at an angle of 120 degrees to each other).

The position and dimensions of the fixed mold 50 are set so that the main body molding cavity Cb, the separate plate molding cavity Cp and the common runner 45 communicate with each other.
Two switching slots 53 forming an angle of 0 degrees are formed. Therefore, the main body molding cavity Cb and the separate plate molding cavity Cp of these cavities Cb, Cp, Ca communicate with the common runner 45 via the switching slot 53 provided on the rotor 52 side, and the injection nozzle The molten resin (not shown) is supplied and filled into the main body molding cavity Cb and the separate plate molding cavity Cp via the sprue portion 42, the common runner 45, and the switching slot 53 in this order. I have.

The main body molding cavity Cb and the abutment cavity Ca among the cavities Cb, Cp and Ca are shown in FIGS. 28 and 29, as can be clearly understood from the description of the basic concept of DRI. As described above, the positions are switched depending on the rotation state of the rotor 52. On the other hand, the separate plate molding cavity Cp
Are always formed at the same position even if the rotor 52 repeats the rotation operation by the normal rotation / reversal of 120 degrees. That is, from the initial state shown in FIGS.
When the mold 2 is rotated 120 degrees and the molds are matched, FIG.
As shown in the figure, the combination of the male mold part 52 # on the fixed mold 50 side and the female mold part 72F2 on the movable mold 70 makes the molding cavity Cb of the main body Sb the same as the female mold part 52F2 on the fixed mold 50 side. The molding cavity Cp of the separate plate Sp is combined with the male mold part 72 # on the movable mold 70 side.
In addition, the cavity Ca for abutment, which combines and abuts both parts in a combination of the female mold part 52F1 on the fixed mold 50 side and the female mold part 72F1 on the movable mold 70 side, has a circumferentially uniform shape ( That is, they are formed at an angle of 120 degrees with each other.

In order to adhere the molded main body Sb and the separate plate Sp to the molding die while holding the molded main body Sb and the separate plate Sp in the abutment cavity Ca, a pump 61 for supplying an adhesive and a connection to the pump 61 are provided. The supplied adhesive supply pipe 62 (see FIGS. 24, 28 and 29) is additionally provided. On the other hand, the abutment cavity Ca is provided with an adhesive supply path 63 having one end connected to the adhesive supply pipe 62 and the other end communicating with the adhesive groove G of the separate plate Sp. The adhesive supply path 63 includes an introduction path 63i provided in the mold plate 72 of the movable mold 70 and a branch path 63d provided in the rotor 52 of the fixed mold 50.

The introduction path 63i is provided so as to extend to the vicinity of the abutment cavity Ca and the main body molding cavity Cb on the mold splitting surface of the mold plate 72. The branch path 63d is provided in the vicinity of the female mold part 52A forming the abutment cavity Ca and the vicinity 52P forming the separate plate molding cavity Cp on the mold splitting surface of the rotor 52, respectively. Are connected to portions corresponding to the adhesive groove G of the separate plate Sp of the female mold parts 52A, 52P forming the cavities Ca, Cp. And
According to the rotation state of the rotor 52, the abutment cavity Ca
On the side, the introduction path 63i and the branch path 63d are connected, and an adhesive supply path 63 is formed, one end of which is connected to the adhesive supply pipe 62 and the other end of which is connected to the adhesive groove G of the separate plate Sp. (See FIGS. 28 and 29).

Accordingly, the adhesive supplied from the adhesive supply pump 61 under pressure is supplied to the adhesive supply pipe 62 and the adhesive supply path 6.
3 (introduction path 63i + branch path 63d), the adhesive is supplied to the adhesive groove G of the separate plate Sp in the abutment cavity Ca. At this time, on the side of the main body molding cavity Cb, the branch passage 63d is formed.
Is not provided, the introduction path 63i is not closed halfway and the adhesive supply path 63 is not formed.

In the above configuration, by closing the movable mold 70 with the fixed mold 50 and clamping the mold,
As for the formation of the cavities Cb, Cp, and Ca, as described above, for example, the initial state of FIG. 28 is obtained. At this time,
In the cavity Ca, the main body molded in the cavity Cb in the previous cycle and the separate plate molded in the cavity Cp are combined and abutted by the rotation of the rotor 52 in the cavity Ca.
By filling molten resin from an injection nozzle (not shown) in this mold-clamped state, a main body is formed in the cavity Cb, and a separate plate is formed in the cavity Cp. In this embodiment, as the material resin, for example, a polyamide resin mixed with glass reinforcing fiber was used. On the other hand, in the abutment cavity Ca, the main body Sb molded in the previous cycle and the separate plate Sp
When the predetermined adhesive is supplied from the adhesive supply pump 61 in a state where the separation plate S
The predetermined adhesive is supplied and filled into the adhesive groove G of p.

In the present embodiment, for example, a thermosetting adhesive is used as the adhesive. This thermosetting adhesive is filled into the adhesive groove G of the separate plate Sp held in the mold as described above, and is cured to some extent at the mold temperature (the temperature of the mold) to form an adhesive force. However, in order to obtain a stronger and more reliable adhesive force, it is more preferable that the assembly of the main body Sb and the separate plate Sp to which the adhesive is applied is taken out of the mold, and then maintained at a predetermined temperature. By performing a heat-curing process in a heating machine or a drier (both not shown) for a predetermined time, the adhesive is finally cured to obtain a predetermined adhesive force.

Further, the mold is opened, and the main body Sb to which the adhesive is applied and the separate plate Sp are separated.
After removing the assembly from the mold, the rotor 52 is
After rotating by 20 degrees (see FIG. 29), the movable mold 50 is again fitted to the fixed mold 70 and clamped, and then, as in the case of the initial state described above (see FIG. 28), the molten resin is removed. By performing the injection / filling and the supply / filling of the adhesive, an assembly of the main body Sb and the separate plate Sp formed by injection molding, and the main body Sb and the separate plate Sp to which the adhesive is applied can be obtained. That is, an assembly of the main body Sb to which the adhesive is applied and the separate plate Sp (that is, the control valve body Sa) is obtained for each one rotation operation of the rotor 52.

As described above, in this embodiment, a pair of synthetic resin divided bodies (the main body Sb and the separate plate Sp) are brought into abutment with each other, and the two divided bodies are joined at this abutting portion. When the synthetic resin molded body (control valve body Sa) having the hollow portion (the hydraulic circuit Bc) is manufactured by this, at least one of the abutting surfaces (in the present embodiment, the abutting surface of the separate plate Sp). Forming a pair of a main body Sb and a separate plate Sp provided with at least a groove (outermost adhesive groove Ga) surrounding the outside of the hydraulic circuit Bc, and a forming die used in the forming step. Each of the above-mentioned divided bodies S
a step of abutting both divided bodies Sb and Sp while holding b and Sp, and filling the outermost adhesive groove Ga with an adhesive in this abutted state to fill the divided bodies (main body). And Sb and a separate plate Sp).

More specifically, the movable mold 50 and the fixed mold 70 are clamped to form a main body formed of a female mold section and a male mold section for molding the main body Sb as the first divided body. After forming the body molding cavity Cb and the separate plate molding cavity Cp including the male mold portion and the female mold portion for molding the separate plate Sp as the second divided body, both molding cavities are formed in the molding process. The main body Sb and the separate plate Sp are molded by injecting the molten resin into Ca and Cp. After the molding process, the movable mold 50 and the fixed mold 70 are opened to correspond to the respective female mold parts. After moving at least one of the two molds relative to the other while holding each of the divided bodies (in this embodiment, rotating by 120 degrees), the two molds are re-mounted. By closing the mold, the main body Sb and the separate plate Sp are brought into abutment with each other in the abutment cavity Ca. In this abutted state, an injection port (adhesive supply) communicating with the outermost adhesive groove Ga is provided. The divided body (the main body Sb and the separate plate Sp) is bonded together by press-fitting the adhesive from the passage 63) and filling the groove Ga. In the present embodiment, in particular, the movable mold and the fixed mold are for so-called DRI (rotary injection molding), and each divided body (main body Sb and separate plate Sp) is formed for each rotation operation. The abutted pair of divided bodies are joined together to obtain a finished product (control valve body Sa) for each rotation operation.

Therefore, according to the present embodiment, the two divided bodies (the main body Sb and the separate plate Sp) are abutted and adhered to each other using the molds of the divided bodies, so that the divided bodies can be suitably used. A stable abutment and pressurized state can be ensured. Further, since the two divided bodies are joined by bonding using an adhesive, the filling pressure of the joining medium (adhesive) into the outermost groove Ga is lower than in the case of joining using a resin. The size of the molded body (control valve body Sa) does not increase due to an increase in the thickness of the divided body. Then, there is no fear that the size of the molded product will be increased, and an injection molding method by a so-called die rotary injection (DRI) method can be applied, so that productivity can be improved.

In particular, the movable type and the fixed type are so-called DR
I (rotary injection molding), and each divided body (main body Sb and separate plate Sp) for each rotation operation
Of the pair of divided bodies joined with the molding of
Finished product (control valve body S
Since a) is obtained, particularly high productivity and quality can be stably obtained.

Further, in the present embodiment, the method of the present invention
Since the present invention is applied to the manufacture of the control valve body Sa having the hydraulic circuit Bc inside, the complicated hydraulic circuit Bc
By forming the control valve body Sa having the above characteristics from a synthetic resin, it is possible to significantly reduce the weight as compared with the case where the control valve body Sa is conventionally manufactured by Al die casting. In addition, the injection molding method based on the so-called DRI method can be applied without increasing the size due to an increase in the wall thickness and the like, and high productivity and high quality can be stably obtained. .

In particular, the control valve body Sa is a main body Sb in which a hydraulic circuit Bc is formed.
And a separate plate Sp that is joined to the main body Sb by abutment. The abutment surface of the separate body Sp has a groove Ga for an adhesive surrounding the outside of the hydraulic circuit Bc, and a hydraulic circuit. Since the groove Gw for the adhesive corresponding to the partition wall Bw of the main body Sb forming the Bc is provided, it is possible to operate without having to interpose a gasket between the main body and the separate plate as in the related art. It is possible to reliably prevent not only leakage of oil to the outside but also leakage between flow paths inside the hydraulic circuit Bc.

In the present embodiment, the main body Sb
Various tests were performed on the adhesive used for bonding (adhesion) between the resin and the separate plate Sp, the shape of the groove filled with the adhesive, and the like. Hereinafter, these tests will be described. First, the main body Sb and the separate plate Sp
When examining the adhesive used for bonding (adhesion) with
An evaluation test of the adhesive strength was performed. This evaluation test was performed for the following three types of adhesives.・ Adhesive I: Three Bond TB2212B (manufactured by Three Bond Co., Ltd.) ・ Adhesive II: Three Bond TB2247B (manufactured by Three Bond Co., Ltd.) ・ Adhesive III: Adhesive for UBE nylon (manufactured by Ube Industries, Ltd.)

Of the above three types of adhesives, adhesives I and I
I is both thermosetting, adhesive I is low viscosity type,
II is of high viscosity type. Examples of synthetic resin samples bonded by these adhesives include PA6 resin and PA6 resin each containing 30% of glass reinforcing fiber.
One of the six resins was used. That is, using the synthetic resin as a material, as shown in FIG. 30, two plate-like samples TP1 and TP2 are prepared, and they are joined with an adhesive (adhesive layer Ad) in an abutting state (adhesive layer Ad). Ad
Thickness: Ta) One test piece TP was prepared. FIG.
At 0, the unit of each dimension number is centimeter (cm)
It is.

The above two types of synthetic resins PA6 resin and P
The above three types of adhesives I, II and III are applied to A66 resin, and the thickness Ta of the adhesive layer Ad is set to 0.5.
mm, 1.0 mm, and 5.0 mm, 14 types of test samples from 1-A to 6-A were prepared as shown in Table 1 below, and the tensile strength and bending strength of each test sample were determined. evaluated. In Table 1, "oven setting (temperature)" is the ambient temperature in the oven (heating tank) when the thermosetting adhesives I and II are subjected to the curing treatment. This is the displayed temperature of the temperature sensor. The “sample temperature” is a value obtained by actually measuring the temperature of the surface of each actual sample by a surface thermometer, separately from the oven set temperature.

[0061]

[Table 1]

That is, three test pieces TP were prepared for each test sample, and the tensile strength and bending strength of each test piece TP were measured. The tensile strength was measured by applying a tensile load to the test piece TP shown in FIG. 30 in the longitudinal axis direction. As for the bending strength, as shown in FIG. 31, the test piece TP was supported by a pair of fulcrums separated by a distance of 5 [cm], and a strength was evaluated by applying a downward load to the center. Table 2 shows curing treatment conditions (thermosetting) and strength evaluation conditions in each test. In Table 2, "time until evaluation"
Is the time for the thermosetting adhesives I and II to be taken out of the oven (heating tank) after the curing process and to carry out the test. During this time, the thermosetting adhesives are stored in a storage room at room temperature of 25 ° C. After this time (600 seconds), the samples were completely cooled and reached 25 ° C., the same as room temperature. As for the adhesive III, the “time until evaluation” is the time during which the sample was stored in a storage room at a room temperature of 25 ° C. from the time of bonding until the test was performed.
5 hours.

[0063]

[Table 2]

FIG. 34 shows the results of each test (tensile strength test results).
And FIG. 35 (result of bending strength test). The data value of each sample in both tests is a numerical value obtained by averaging the test results for three test pieces. Note that FIG.
Samples 7 and 8 show the joining strength (tensile strength) by vibration welding and resin welding by the DRI method when the joining area is set to be substantially the same. The sample 7 (vibration welding) is a case where PA6 resins containing 30% of glass reinforcing fibers are vibration-welded. Sample 8 (resin welding by DRI method) corresponds to a case in which half-pieces are welded to each other with a secondary resin by DRI molding using PA6 resin containing 30% of glass reinforcing fiber as a material. , About 400kgf / cm
^{About 2} filling pressures are required. Since the vibration welding method and the resin welding method in DRI molding are the same as conventionally well-known methods, further description will be omitted.

Further, FIG. 36 and FIG. 37 show that the tensile strength test data of FIG.
FIG. 36 shows the case where the adhesive I was used, and FIG. 37 shows the case where the adhesive II was used. Incidentally, in the graphs of FIG. 36 and FIG. 37, a circle indicates a case where the test material is PA6 resin,
In addition, the triangles indicate the case where the test material is PA66 resin, respectively.

As can be seen from the graphs of FIGS. 34, 36 and 37, in each of the adhesives I and II, the tensile strength increases as the thickness Ta of the adhesive layer Ad increases. In particular, as can be clearly understood from the graphs of FIGS. 36 and 37, when the thickness Ta of the adhesive layer Ad is approximately 2 [mm] or more, a high tensile strength can be more stably secured. Also, comparing the joining with adhesive I (low viscosity type) and the joining with adhesive II (high viscosity type),
When the thickness Ta of the adhesive layer Ad is 1 [mm] or 5 [mm], the adhesive II (the curing time is set longer than the adhesive I) has higher strength. Can be However, when the thickness Ta of the adhesive layer Ad is small (particularly, the thickness T
When a = 0.5 mm: Same curing time (10 minutes)
Is set to In), the difference between the two is extremely small. Incidentally, the adhesive III has a significantly lower tensile strength than the case where the thickness Ta of the adhesives I and II is 0.5 mm. Also, the adhesive strength is remarkably inferior to that of the case of vibration welding, and it is considered that it is difficult to put to practical use.

Furthermore, when the joining using the adhesive I or II is compared with the joining by vibration welding, the thickness Ta of the adhesive layer Ad having the lowest tensile strength among the adhesives I having the lowest tensile strength is equal to 0.1. It was found that even in the case of 5 mm (sample 1-A), strength equal to or higher than that obtained by joining by vibration welding can be obtained. Therefore, even when joining with the low viscosity type adhesive I which has relatively high fluidity and is advantageous for filling in the groove, it is equivalent to vibration welding conventionally widely used, or the thickness Ta of the adhesive layer Ad. It has been found that if the thickness is set to be thicker, a higher tensile strength can be secured, and it is sufficiently practical.

As can be seen from the graph of FIG.
Bonding with low-viscosity adhesive I can withstand equal or greater bending loads than bonding with high-viscosity adhesive II. It is considered to have adequate aptitude.
The adhesive III is considerably inferior in bending strength as compared with the case where the thickness Ta of the adhesives I and II is Ta = 0.5 mm.

Next, a test was conducted to examine the relationship between the curing temperature and time and the adhesive strength (tensile strength). This test was performed in the same manner as in the tensile strength test described above, using the above-mentioned adhesive I (a low-viscosity type thermosetting adhesive). However, the test piece was prepared by joining (adhering) the PA66 resin and the PPS resin. The test results are shown in FIG. This figure 3
In the graph of FIG. 8, curves (or straight lines) K1, K2, and K3 indicate curing treatment temperatures of 150 ° C. and 120 ° C., respectively.
K4 represents the adhesive strength obtained by the above-described vibration welding.

As can be seen from the test results (FIG. 38), the higher the curing temperature, the shorter the time required to develop the same adhesive strength (curing time), and the lower the curing temperature. If the same, the longer the curing time, the higher the adhesive strength (tensile strength) is obtained. In addition, for all curing temperatures, the characteristic curves (or straight lines) K1, K2, and K3 intersect with the broken line K4 indicating the adhesive strength obtained by vibration welding, and the low-viscosity thermosetting adhesive is used. It was found that even when the agent I was used, by setting the curing treatment temperature and time appropriately, a higher adhesive strength could be obtained than in the case of vibration welding.

Next, a test was conducted to evaluate the fluidity of the adhesive. FIGS. 32 and 33 schematically show a test apparatus used for the fluidity evaluation test. As shown in these figures, this test apparatus is composed of a pair of upper and lower base plates BP1 and BP2 and a pair of left and right adjustment plates Ac interposed therebetween, and as a whole,
An apparatus main body J formed in a plate shape is provided. Inside the apparatus main body J, upper and lower base plates BP1 and BP2 are provided.
Groove Gj extending in the longitudinal axis direction between the left and right adjustment plates Ac
Is formed, and one end of the groove portion Gj is connected to a plug member Pg.
Is closed. 32 and 33, the unit of the number indicating the dimension is millimeter (mm). The groove Gj has a rectangular cross-sectional shape, and its width Wg and depth Dg can be adjusted by changing the width and thickness of the adjusting plate Ac. In the present embodiment, a test was performed with the width Wg of the groove Gj set to 2 [mm] and the depth Dg set to 0.5 [mm].

In the vicinity of one end of the groove Gj (the end closed by the plug member Pg), a pipe-shaped injection part Ji is inserted and joined from above. An adhesive supply pipe (not shown) connected to an adhesive supply pump is connected to the upper end side of the injection part Ji. still,
In the present embodiment, the device main body J and the like are formed of a PA resin containing a PC resin or a PM @ A resin and glass reinforcing fibers. In the above configuration, the apparatus body J
By driving the adhesive supply pump and supplying the adhesive at a predetermined discharge pressure while the
The adhesive is injected into the groove Gj from the injection part Ji, and flows through the groove Gj by a length (flow length) according to the flow characteristics. At this time, it can be determined that the fluidity is superior as the fluid flows faster and further away at the same pressure.

In this test, the flow length of the low-viscosity thermosetting adhesive I was measured at an ambient temperature of 22 ° C. while changing the adhesive supply pressure in the range of 1 to 4 [kgf / cm ² ]. did. The viscosity of the adhesive used in the test was 25,000 [cp] at a temperature of 25 ° C. The test results are shown in FIG. As can be seen from the graph of FIG. 39, the higher the supply pressure, the longer the flow length, and at any pressure, a considerably long flow length is obtained 1 to 3 minutes after the start of supply. In the case of the control valve body Sa described above, the flow length required for joining (adhesion) between the main body Sb and the separate plate Sp is about 130 mm [mm], and a time of 1 minute or less (4 [kgf]) at any pressure. / Cm ² ]
(0 second or less).

As described above, in the case of joining (welding) the halves with the secondary resin in the so-called DRI molding, the flowability of the molten resin is low, so that a high pressure of approximately 400 [kgf / cm ² ] is applied. It is necessary to supply a molten resin (secondary resin for joining), and therefore, the thickness of the wall constituting the groove through which the resin flows must be set to be considerably large. On the other hand, in the case of joining (adhering) the halves using an adhesive, sufficient flowability of the adhesive can be secured at a lower pressure than in the case of resin welding. The wall thickness of the constituent wall can be considerably reduced.

Next, the effect of the cross-sectional shape of the groove on the bonding (adhesion) strength was evaluated. Evaluation of this groove shape,
This was performed for each of the grooves G to G5 having the shapes and dimensions shown in FIGS. That is, for each of the grooves G to G5,
The unit adhesive length (1c
m) per unit area (the area where the adhesive in the groove and the mating member come into contact) is determined, and the bonding strength (tensile strength) of the adhesive is determined.
Was multiplied to calculate the calculated strength, and the strength was evaluated based on this value. In addition, from the shape and dimensions of the groove, the complexity of the structure of the molding die and the quality stability of the obtained product were also evaluated. As the adhesive, the above-mentioned low-viscosity type thermosetting adhesive I is employed, and when calculating the calculated strength, the thickness Ta of the adhesive layer Ad is 0.5 [mm], which is the thinnest ( In this case, the value of the joint strength appears the lowest (66 [k
gf / cm ² ]). Table 3 shows the evaluation results.

[0076]

[Table 3]

As can be seen from Table 3, in the case of the adhesive groove G5 shown in FIG. 21, the calculated strength is the highest, but the mold structure is the most complicated and the quality stability is the lowest. Therefore, the overall evaluation is also low. On the other hand, in the case of the adhesive groove G3 shown in FIG. 19, the calculated strength is the second,
It has the second highest ranking in terms of mold structure and quality stability, and has the highest overall rating. Further, in the case of the adhesive groove G shown in FIG. 17, although the calculated strength is the lowest, the mold structure is considered to be the simplest and the quality stability is also the highest, and the overall evaluation is the second. . The evaluation order of the quality stability of the adhesive groove portions G2, G3 and G4 is second, but this is due to the fact that these groove portions G2, G3
This shows that the evaluations of the quality stability of G3 and G4 are equivalent.

In the above embodiment, the control valve body Sa of an automatic transmission (automatic transmission: AT) for a vehicle and its manufacture have been taken as an example. However, the present invention is limited to such a case. It is not the case that a pair of synthetic resin divided bodies are abutted with each other, and the two divided bodies are joined at the abutting portion to produce various other synthetic resin molded bodies having a hollow portion. Even it can be applied effectively. Further, in the above-described embodiment, the so-called DRI method was applied when manufacturing the synthetic resin molded body, but the present invention is not limited to such a manufacturing method.
It can be effectively applied to the case where the method I is used. As described above, the present invention is not limited to the above-described embodiment, and without departing from the gist thereof.
It goes without saying that various improvements or design changes are possible.

[0079]

According to the method of manufacturing a synthetic resin molded article according to the first invention of the present application, a pair of synthetic resin divided bodies are brought into contact with each other and joined to each other to form a synthetic resin molded article having a hollow portion. When manufacturing the body, at least one of the abutting surfaces is molded at least a pair of synthetic resin divided body provided with a groove surrounding the outside of the hollow portion,
In a state where each of the divided bodies is held in the molding die used in the molding step, the two divided bodies are abutted with each other, and in this abutted state, the groove is filled with an adhesive to bond the two divided bodies together. Therefore, by performing the abutment and adhesion between the two divided bodies using the molds of the respective divided bodies, it is possible to stably secure a suitable abutment and pressurized state between the divided bodies. In addition, since the two divided bodies are joined by bonding using an adhesive, the filling pressure of the joining medium (adhesive) into the groove portion is lower than in the case of joining using a resin. There is no increase in the size of the compact due to an increase in the wall thickness of the compact. Then, there is no fear that the size of the molded body will be increased, and the injection molding method by the so-called die rotary injection (DRI) method or die slide injection (DSI) method can be applied, and productivity can be improved. Can be improved.

According to the second aspect of the present invention, basically, the same effects as those of the first aspect can be obtained. In particular, by relatively sliding or rotating the movable mold and the fixed mold of the molding die, a so-called DSI method or DRI method can be applied, and high productivity and quality can be stably obtained. .

Further, according to the third aspect of the present invention, the movable mold and the fixed mold are for so-called DRI (rotary injection molding), and each time the rotary operation is performed, the movable mold and the fixed mold are in abutment with each other. Since the pair of divided bodies are joined to each other, and a finished product is obtained for each rotation operation, particularly high productivity and quality can be stably obtained.

Further, according to the synthetic resin molded article according to the fourth invention of the present application, a synthetic resin molded article having a hollow portion obtained by abutting and joining a pair of synthetic resin divided bodies, The same effects as those of any one of the first to third aspects of the invention can be obtained.

Further, according to the fifth invention of the present application,
Basically, the same effect as the fourth invention can be obtained. In particular, since the above-mentioned synthetic resin molded body is a control valve body having a hydraulic circuit inside, by forming a control valve body having a complicated hydraulic circuit inside with synthetic resin, conventionally, an Al die casting It is possible to significantly reduce the weight compared to the case where it was manufactured by using the above method. Moreover, it is possible to apply the so-called injection molding method by the DRI method or the DSI method without increasing the size due to an increase in the wall thickness, etc., and to stably obtain high productivity and quality. Will be possible.

Further, according to the sixth invention of the present application,
Basically, the same effects as those of the fifth aspect can be obtained. In particular, the control valve body includes a main body in which a hydraulic circuit is formed, and a separate plate which abuts and is joined to the main body. The groove for the adhesive surrounding the main body and the groove for the adhesive corresponding to the partition of the main body forming the hydraulic circuit are provided, so that the gasket is inserted between the main body and the separate plate as in the conventional case. Without the need for intervening, it is possible to reliably prevent not only the leakage of the hydraulic oil to the outside but also the leakage between the flow paths inside the hydraulic circuit.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram of a combination of a fixed mold and a movable mold of a DRI mold for explaining a basic concept of a rotary injection molding (DRI) method.

FIG. 2 is an explanatory plan view of a mold surface of the fixed mold.

FIG. 3A is a vertical sectional view taken along line AA of FIG. 1 in a state where the fixed mold and the movable mold are matched. (B) BB of FIG. 1 in a state where the fixed mold and the movable mold are matched.
FIG.

FIG. 4A is an explanatory plan view of a fixed mold surface according to a modification of the present embodiment. (B) It is a plane explanatory view of the mold surface of a movable type concerning the above-mentioned modification.

FIG. 5A is an explanatory plan view of a fixed mold surface according to another modification of the present embodiment. (B) It is a plane explanatory view of the mold surface of a movable type concerning the other above-mentioned modification.

6A is a vertical sectional view taken along the line AA of FIG. 1 in a state where the fixed mold and the movable mold are matched with each other. (B) FIG. 2 is an explanatory longitudinal sectional view taken along the line BB of FIG. 1 in a state where a dummy product after the fixed mold and the movable mold has been set in a cavity.

FIG. 7 (a) is a vertical sectional view taken along the line AA of FIG. 1 in a state where a molding cavity is filled with resin. (B)
FIG. 1B with the molding cavity filled with resin
FIG. 4 is a vertical sectional view taken along line B.

FIG. 8 (a) FIG. 1 in a mold open state after resin filling.
FIG. 4 is a vertical sectional view taken along line AA of FIG. FIG. 2B is an explanatory longitudinal sectional view taken along the line BB of FIG. 1 in a mold open state after filling with resin.

FIG. 9 is a conceptual diagram of a combination of a fixed mold and a movable mold in a state where the fixed mold is rotated 120 degrees from the initial state of FIG.

10 (a) is an explanatory longitudinal sectional view taken along the line AA of FIG. 9 in a state where the fixed mold and the movable mold have been mated after the rotation. FIG.
FIG. 10 (b) is a vertical sectional view taken along the line BB of FIG. 9 in a state where the fixed mold and the movable mold have been mated after the rotation.

11A is a vertical sectional view taken along the line AA of FIG. 9 in a state where a molding cavity is filled with resin. (B)
FIG. 10 is an explanatory longitudinal sectional view taken along the line BB of FIG. 9 in a state where the molding cavity is filled with resin.

12 (a) is an explanatory longitudinal sectional view taken along the line AA of FIG. 9 in a mold open state after filling with resin. (B) It is a BB longitudinal sectional explanatory view of FIG. 9 in the mold open state after resin filling.

13 is a conceptual diagram of a combination of a fixed mold and a movable mold in a state where the fixed mold is inverted by 120 degrees from the rotation state of FIG. 9;

FIG. 14 is an explanatory plan view showing a main body of a control valve body and a hydraulic circuit thereof according to the embodiment of the present invention.

FIG. 15 is an explanatory longitudinal sectional view taken along line Y15-Y15 in FIG. 14 showing a state in which a separate plate is combined with the main body.

FIG. 16 is an enlarged longitudinal sectional view of a portion Y16 in FIG. 15, which is an enlarged view of a joint portion between the main body and the separate plate.

FIG. 17 is an enlarged vertical cross-sectional explanatory view of an adhesive groove provided at a joint portion in FIG. 16;

FIG. 18 is an enlarged vertical cross-sectional explanatory view showing a modified example of the adhesive groove portion.

FIG. 19 is an enlarged vertical cross-sectional explanatory view showing another modified example of the adhesive groove portion.

FIG. 20 is an enlarged vertical cross-sectional explanatory view showing still another modified example of the adhesive groove portion.

FIG. 21 is an enlarged vertical cross-sectional explanatory view showing still another modified example of the adhesive groove portion.

FIG. 22 is an enlarged vertical cross-sectional explanatory view of a groove portion for molten resin when the main body and the separate plate are joined with molten resin.

FIG. 23 is an explanatory longitudinal sectional view taken along the line Yb-Yp in FIGS. 28 and 29, showing a matching state of the DRI mold according to the embodiment of the present invention.

FIG. 24 is an explanatory longitudinal sectional view taken along the line Ya-Yp in FIGS. 28 and 29, showing a matching state of the DRI mold.

FIG. 25 is an explanatory longitudinal sectional view showing, in an enlarged manner, a main body molding cavity obtained in a mold matching state of the DRI mold.

FIG. 26 is an explanatory longitudinal sectional view showing, in an enlarged manner, a separate plate molding cavity obtained in a state where the molds are aligned.

FIG. 27 is an explanatory longitudinal sectional view showing, in an enlarged manner, an abutment cavity obtained in a state in which the molds are aligned.

FIG. 28 is a schematic explanatory view showing a cavity position on a mold matching surface of the DRI mold.

FIG. 29 is a schematic explanatory view showing a rotor rotation state in which the cavity position on the mold matching surface of the molding die differs by 180 degrees.

FIG. 30 is a perspective view showing a schematic shape and dimensions of a test piece used in an adhesive strength evaluation test of an adhesive.

FIG. 31 is an explanatory view schematically showing a bending strength test using the test piece.

FIG. 32 is an explanatory plan view of a device main body of a test device used for an adhesive fluidity evaluation test.

FIG. 33 is an explanatory longitudinal sectional view taken along line Y33-Y33 in FIG. 32;

FIG. 34 is a graph showing test results of a tensile strength evaluation test of an adhesive.

FIG. 35 is a graph showing a test result of a bending strength evaluation test of the adhesive.

FIG. 36 is a graph showing a correlation between an adhesive layer thickness and a tensile strength of a low-viscosity type thermosetting adhesive.

FIG. 37 is a graph showing a correlation between an adhesive layer thickness and a tensile strength of a high-viscosity type thermosetting adhesive.

FIG. 38 is a graph showing the correlation between the curing time and the adhesive strength of a low-viscosity thermosetting adhesive.

FIG. 39 is a graph showing the flow length versus time of a low-viscosity thermosetting adhesive.

[Explanation of symbols]

 Reference numeral 50: fixed mold 52: rotor 52F1, 52F2: fixed-mold-side female molded part 52 固定: fixed-mold-side male molded part 61: adhesive supply pump 63: adhesive supply path 70: movable mold 72: mold plate 72F1 , 72F2: Female mold portion on movable mold side 72: Male mold portion on movable mold side Bc ... Hydraulic circuit Bw ... Partition wall Ca ... Cavity for abutment Cb ... Cavity for molding a main body Cp ... Cavity for molding a separate plate G ... Adhesive groove Ga: Outermost adhesive groove Gw: Adhesive groove corresponding to partition Sa: Control valve body Sb: Main body Sp: Separate plate

Claims (6)

[Claims] 1. A manufacturing method for manufacturing a synthetic resin molded article having a hollow portion by bringing a pair of synthetic resin divided bodies into contact with each other, and joining the two divided bodies at the abutting portion. A molding step of molding a pair of synthetic resin divided bodies provided with at least one groove surrounding the outside of the hollow portion on one of the abutting surfaces; and each of the divided bodies in a molding die used in the molding step. An abutting step of abutting the two divided bodies with each other in a held state; and an adhering step of filling the groove portion with an adhesive and adhering the two divided bodies in the abutted state. A method for producing a synthetic resin molded article having a hollow portion. 2. A fixed mold having at least a female mold forming part for forming a first split body and a male mold forming part for forming a second split body, and a male mold for forming at least the first split body. A movable mold having a molded part and a female mold part for molding the second divided body, wherein the movable mold and the fixed mold are openable and closable with each other and at least one of them is relatively to the other. The movable mold and the fixed mold are clamped to form a first molded part and a male molded part for molding the first divided body.
After forming the divided body molding cavity and the second divided body molding cavity formed by the male mold part and the female mold part for molding the second divided body, in the molding step, the first and second molded bodies are formed.
The first and second divided bodies are molded by injecting the molten resin into the molding cavity of the above. After the molding step, the movable mold and the fixed mold are opened,
After moving at least one of the two molds relative to the other while holding the divided bodies corresponding to the respective female mold parts, the first and second molds are re-clamped. The two divided bodies are brought into abutment with each other, and in this abutted state, the two divided bodies are adhered to each other by press-fitting an adhesive from an injection port communicating with the groove and filling the inside of the groove. The method for producing a synthetic resin molded article having a hollow portion according to claim 1. 3. One of the movable mold and the fixed mold is rotatable by a predetermined angle with respect to the other, and each of the molds has a male / female / female repetition order in a rotation direction at the predetermined angle. It is for rotary injection molding provided with at least one male molded part and two female molded parts, and a pair of divided bodies abutted on the molding of each divided body at every rotation operation. 3. The method according to claim 2, wherein a finished product is obtained for each rotation operation. 4. A synthetic resin molded body having a hollow portion produced by abutting a pair of synthetic resin divided bodies with each other, and joining the two divided bodies together at the abutting portion. A synthetic resin molded article produced by the production method according to any one of claims 1 to 3. 5. The synthetic resin molded product according to claim 4, wherein the synthetic resin molded product is a control valve body having a hydraulic circuit therein. 6. The control valve body includes a main body in which a hydraulic circuit is formed, and a separate plate that abuts and is joined to the main body. 6. The synthetic resin molded body according to claim 5, wherein a groove for the adhesive surrounding the outside of the circuit and a groove for the adhesive corresponding to the partition of the main body forming the hydraulic circuit are provided. .