JP2020078910A - Injection molded body manufacturing apparatus and manufacturing method, and resin molded products - Google Patents

Abstract

To make it possible to injection-mold a desired part and an anti-wind noise/light leakage material in the same mold, and to join the anti-wind noise/light leakage material that was molded in the previous process to another part.SOLUTION: An injection molding apparatus 30 comprises a turntable 5, a first, second and third mold disposed on the turntable 5, a fourth, fifth and sixth mold for opening and tightening the first, second and third mold, and a first injection device 12, a second injection device 13 and a third injection device 14 for injecting resin into the molds. Furthermore, a housing and an anti-wind noise/light leakage material are injection molded in the same mold, and after the anti-wind noise/light leakage material is transferred between the molds, the lens is molded and the anti-wind noise/light leakage material is bonded to the lens in the lens molding process.SELECTED DRAWING: Figure 1

Description

  TECHNICAL FIELD The present invention relates to an apparatus and method for manufacturing an injection-molded body that is attached to an automobile part, and a resin-molded product.

  2. Description of the Related Art As an example of an injection molded body that is attached to a vehicle door mirror or the like, an injection molded body in which a lens and a housing are integrally molded is known. In this injection molded body, two members made of two kinds of resin materials are integrated. A gap is likely to be formed at the joint between the door mirror and the injection-molded body.If the gap is formed, wind noise may be generated by the gap during traveling, or light may leak from the gap at the joint between the door mirror and the injection-molded body. Occur. As a countermeasure against the wind noise and light leakage, a countermeasure member such as packing is attached to the surface of the lens of the injection-molded body after the completion of injection molding, by retrofitting to the above-mentioned joining portion.

  Regarding the manufacturing apparatus and the manufacturing method of the injection-molded body, Patent Documents 1 and 2 disclose the structure and the manufacturing method thereof. While rotating the turntable and simultaneously performing a plurality of processes on the turntable, It is disclosed to integrate members made of different materials.

JP, 2016-117221, A JP, 2010-179511, A

  However, in the manufacturing apparatus and manufacturing method of the injection-molded body described in Patent Documents 1 and 2 above, although resin molding that integrates two members can be performed, a member for preventing wind noise and light leakage is provided in the manufacturing device. It cannot be installed.

  Therefore, a countermeasure member for preventing wind noise and light leakage, such as packing, will be attached to the injection-molded body in a separate step. If the above-mentioned countermeasure member is post-molded after injection molding, the material cost and assembling man-hours increase.

  Further, if an automatic assembling machine for automatically assembling the above-mentioned countermeasure members is adopted, investment is required, and even in the case of automatic assembling, the number of man-hours required for retrofitting increases. Further, when the shape of the countermeasure member is complicated, it is a problem that automatic assembly itself is difficult.

  In addition, after the secondary injection for joining the two members, if the countermeasure member is assembled in another process, an intermediate stock is generated. Furthermore, since the injection-molded body that has undergone the secondary injection is taken out from the manufacturing apparatus once, there is a risk that foreign matter may adhere due to static electricity, and product variations may occur due to backlash during assembly and setting.

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

  One aspect of the present invention is to inject a resin into a mold to mold first, second and third members, and to bond the third member to the second member when molding the second member. It is an apparatus for manufacturing an injection molded body, which performs a secondary injection and a secondary injection in which a resin is injected into a mold to integrate the second member and the first member to which the third member is joined. .. An injection-molded body manufacturing apparatus includes a turntable that reciprocally rotates, first, second, and third molds that are arranged on the turntable at predetermined intervals along the rotation direction of the turntable, and the first and second molds. First, fourth, fifth and sixth molds which are opened and clamped with respect to the first, second and third molds, and first, second and sixth molds for injecting resin into the molds which have been clamped. A first injection control and a second injection are performed on the first, second and third injection devices by performing first position control and second position control on the turn table and the third injection device. And a control unit that executes 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 a first rotation position where the third mold and the sixth mold face each other, and the controller executes the second position control, the first mold and the sixth mold The turntable is rotated to a second rotation position where the mold faces, the second mold and the fourth mold face each other, and the third mold and the fifth mold face each other. To do. When the controller executes the first injection control after the first position control, the first injection device performs the primary injection, and the first injection is performed in the first and fourth molds. The first member and the third member are molded, the secondary injection is performed by the second injection device, and the second member and the first member in which the third member is joined in the second and fifth molds. The member is integrated, and the primary injection is performed by the third injection device, and the second member is molded in the third and sixth molds and the third member is formed into the second member. Bonding is done. Further, 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 injection is performed in the second and fourth molds. One 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 second injection is performed by the third injection device, and the third member is joined in the first and sixth molds. And are integrated.

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

  Another aspect of the present invention is to inject a resin into a mold to mold the first, second and third members, and to bond the third member to the second member when molding the second member. A method of manufacturing an injection-molded article, comprising: a primary injection; and a secondary injection in which a resin is injected into a mold to integrate the second member and the first member to which the third member is joined. is there. A method of manufacturing an injection-molded article includes a turntable that reciprocally rotates, first, second and third molds arranged on the turntable at predetermined intervals along the rotation direction of the turntable, and the first and second molds. First, fourth, fifth and sixth molds which are opened and clamped with respect to the first, second and third molds, and first, second and sixth molds for injecting resin into the molds which have been clamped. A first injection control and a second injection are performed on the first, second and third injection devices by performing first position control and second position control on the turn table and the third injection device. An apparatus for manufacturing the injection-molded body, which includes a control unit that executes control, is prepared. 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 a first rotation position where the third mold and the sixth mold face each other, and the controller executes the second position control, the first mold and the sixth mold The turntable is rotated to a second rotation position where the mold faces, the second mold and the fourth mold face each other, and the third mold and the fifth mold face each other. To do. When the controller executes the first injection control after the first position control, the first injection device performs the primary injection, 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 second member and the first member are formed by joining the third member in the second and fifth molds. The member is integrated, and the primary injection is performed by the third injection device, and molding of the second member and joining of the third member to the second member in the third and sixth molds. And do. Further, 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 injection is performed in the second and fourth molds. 1st member and said 3rd member are shape|molded, the said 1st injection is performed by said 2nd injection apparatus, In said 3rd, 5th metal mold|die, the said 2nd member is shape|molded and said 3rd to said 2nd member. The second member and the first member are joined together, and the second 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 a rotation direction of the turntable, and have an angle of 120° with respect to a rotation center of the turntable. The turntable is reciprocally moved between the first rotation position and the second rotation position that form

  In another aspect of the present invention, the second member is the third member that is injection-molded in the third and fifth molds or the third and sixth molds and is arranged in advance in the mold. To be joined.

  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 formed. The member is moved to the inside of 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 by the same resin material in the same process and in the same mold.

  Another aspect of the present invention is a resin molded product formed by the method for producing an injection molded body, comprising a housing as the first member made of a non-translucent resin, and the first member made of a translucent resin. A lens as two members and a wind noise/light leakage prevention member as the third member, which is made of a non-translucent resin, and the wind noise/light leakage prevention member is provided along the outer peripheral portion of the lens. Has been.

  According to the present invention, in addition to integrally molding two members, it is possible to mold one member and a wind noise/light leakage prevention member in the same process with a single injection molded body manufacturing apparatus. That is, one member and the wind noise/light leakage prevention member can be injection-molded on the turntable with the same mold in the same process. Furthermore, when another member is injection-molded by another mold in the same step, the wind noise/light leakage prevention member molded in the previous stage can be joined to the other member. As a result, the molding time of the injection molded body can be shortened. Furthermore, the precision of injection molding can be improved. After molding the wind noise/light leakage prevention member, the robot transfers it to the lens molding die to mold the lens and join the lens with the wind noise/light leakage prevention member. It can be manufactured without any intermediate stock. Further, since the housing and the wind noise/light leakage prevention member are injection-molded in the same mold, the wind noise/light leakage prevention member is not molded in a separate process, which reduces the number of workers and man-hours. You can This makes it possible to reduce processing costs. Further, in the lens molding die, since the wind noise/light leakage preventing member is joined to the lens in the same step as the lens molding, it is possible to reduce variations in the attachment of the wind noise/light leakage preventing member. As a result, variations in the assembly of the injection molded body (resin molded product) can be suppressed, and the quality of the injection molded body can be improved.

It is a schematic diagram which shows the structure of the manufacturing apparatus of the injection molded body of this invention. It is a schematic diagram which shows the process in each position after rotating the turntable of the injection molded body manufacturing apparatus shown in FIG. 1 120 degrees counterclockwise. It is a conceptual diagram which shows the structure of the injection molding apparatus which is an example of the manufacturing apparatus of the injection molded body shown in FIG. It is a top view which shows the structure of the injection molded body manufactured by the injection molding apparatus shown in FIG. It is a figure which shows the assembly procedure in the manufacturing method of the injection molded body of this invention, (a) is an assembly procedure in a 1st rotation position, (b) is an assembly procedure in a 2nd rotation position. FIG. 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, (a) is a housing molding die, and (b) is a lens molding die. It is a type. It is a conceptual diagram which shows the arrangement|positioning position of each metal mold|die of the manufacturing apparatus of the injection molded body shown in FIG. 1, (a) is a 1st, 2nd, 3rd metal mold, (b) is a 4th, 5th, 6 This is the layout position of the mold. (A), (b), (c) is a conceptual diagram which shows the injection molding process in a 1st rotation position. (A), (b), (c) is a conceptual diagram which shows the injection molding process in a 2nd rotation position. FIG. 6 is a perspective view showing a structure on a front surface side of a housing formed in a housing molding step in the method for manufacturing the injection molded body shown in FIG. 5. It is a perspective view which shows the structure of the back surface side of the housing shown in FIG. FIG. 6 is a perspective view showing a structure of a wind noise/light leakage prevention member formed in a housing molding step in the method of manufacturing the injection molded body shown in FIG. 5. FIG. 6 is a perspective view showing a structure of a bonded body of a lens and a wind noise/light leakage prevention member formed in a lens molding step in the method for manufacturing the injection molded body shown in FIG. 5. FIG. 6 is a perspective view showing a structure of a lens-housing molded body formed in a secondary molding step in the method for manufacturing the injection molded body shown in FIG. 5. FIG. 15 is a perspective view showing a structure in which the housing and the wind noise/light leakage prevention member are removed from the lens-housing molded body shown in FIG. 14. FIG. 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 article shown in FIG. 5.

  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 a primary injection in which a resin is injected into a mold to mold a first member, a second member and a third member, and The first member, the second member, and the third member, which are molded by primary injection, are transferred to another mold, and resin is injected into the mold to join the third member to the second member. Secondary injection is performed to integrate a 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 body, a lamp 1 attached to a door mirror of an automobile as shown in FIG. 4 is taken up, and further, as an example of the first member which is a constituent member of the lamp 1, a housing is used. 2 will be taken up, and the lens 3 will be taken up as an example of the second member which is a constituent member of the lamp 1. That is, the injection molded body of the present embodiment is the lamp 1 in which the housing 2 and the lens 3 are integrally molded. The housing 2 is made of, for example, a non-translucent resin such as a polycarbonate resin, and the lens 3 is made of a transparent resin such as an acrylic resin.

  In this embodiment, injection molding of the housing 2, the lens 3, or the wind noise/light leakage prevention member (third member) 17 by any of the molds of the injection molding device 30 is called primary injection. Further, the lens 3 to which the wind noise/light leakage preventing member 17 is joined and the housing 2 are integrated by any one of the molds of the injection molding device 30 to mold an injection molded body (lamp 1 shown in FIG. 4). Is called secondary injection (secondary molding).

  The wind noise/light leakage prevention member 17 is a resin member for preventing wind noise and light leakage that occur during traveling in the lamp 1 attached to the door mirror of an automobile. The wind noise/light leakage prevention member 17 is made of, for example, an opaque resin such as an elastomer or a polycarbonate resin. In the present embodiment, the case where the wind noise/light leakage prevention member 17 is made of, for example, a plica resin is described. That is, in the present embodiment, a case will be described in which the housing 2 and the wind noise/light leakage prevention member 17 are molded from the same resin material.

  Next, the injection molding apparatus (manufacturing apparatus for injection molded body) 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 positioned at a predetermined angle with respect to the first rotation position and the rotation center C. It has a rotating turntable 5. In this embodiment, the case where the predetermined angle is 120° will be described. That is, the first rotation position and the second rotation position are positions that form an angle of 120° with the rotation center C of the turntable 5.

  Further, the injection molding device 30 includes a first die 6, a second die 7 and a third die 8 arranged on the turntable 5 at predetermined intervals along the rotation direction of the turntable 5. There is. In the present embodiment, in the case where the turntable 5 is provided with the first die 6, the second die 7 and the third die 8 arranged at an angle of 120° with respect to the rotation center C. Will be described. That is, the first mold 6, the second mold 7, and the third mold 8 are arranged on the turntable 5 at 120° intervals along the rotation direction of the turntable 5.

  Then, the injection molding device 30 includes a fourth mold 9, a fifth mold 10, and a sixth mold which perform mold opening and mold clamping with respect to the first mold 6, the second mold 7, and the third mold 8. A mold 11 is provided. Further, the first injection device 12, the second injection device 13, and the third injection device 14 for injecting the resin into the mold that has been clamped, the reciprocating rotation (turning) operation of the turntable 5, the mold opening and the mold clamping. Therefore, the fourth die 9, the fifth die 10 and the sixth die 11 are moved toward or away from any of the first die 6, the second die 7 and the third die 8. A control unit 16 for controlling the injection operation such as the operation of causing the injection, the injection device used, the resin used, the injection timing, and the like. The control unit 16 controls the turntable 5 to execute the first position control and the second position control, for example, and further controls the first injection device 12, the second injection device 13, and the third injection device. The device 14 is controlled to execute the first injection control or the second injection control.

  Each of the first die 6, the second die 7 and the third die 8 provided on the turntable 5 is a lower die. Among them, 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 molds are opened. is there. 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 detached from the mold when the mold is opened.

  On the other hand, above the turntable 5, the first mold 6, the second mold 7 and the third mold 8 are arranged corresponding to the respective stop positions, and the first mold 6 and the second mold 8 are arranged. A fourth die 9, a fifth die 10 and a sixth die 11 which are upper dies of the seventh die 3 and the third die 8 are provided. Each of the fourth mold 9, the fifth mold 10, and the sixth mold 11 moves up and down to clamp and mold the first mold 6, the second mold 7, and the third mold 8. Open it. 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 of the first mold 6, the second mold 7, and the third mold 8. Has been.

  The fourth mold 9 is a mold for molding the wind noise/light leakage prevention member 17, and the side where the injection-molded wind noise/light leakage prevention member 17 remains in the mold when the mold is opened. Is the male type. The fifth mold 10 and the sixth mold 11 are molds for molding the lens 3 and for joining the wind noise/light leakage prevention member 17 to the lens 3, and are injection molded when the molds are opened. The formed 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 for which secondary injection (secondary molding) is performed, and at the time of secondary injection, the lamp 1 molded by secondary injection is It does not remain in the fifth mold 10 and the sixth mold 11.

  Further, as shown in FIG. 7, each of the first die 6, the second die 7, the third die 8, the fourth die 9, the fifth die 10 and the sixth die 11 is injected. A cavity 18 is formed according to the shape of the molded body to be molded.

  In addition, 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 9 is further attached. A third injection device 14 is attached to the mold 11, and each control unit 16 controls to inject a necessary resin at a necessary 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 have a primary injection for molding the lens 3 and joining the wind noise/light leakage prevention member 17 to the lens 3, or the wind noise/light leakage prevention member 17. Either one of secondary injection for injecting an unifying resin (see FIG. 15) 4 for unifying the joined lens 3 and housing 2 is performed.

  In addition, in the injection molding device 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 includes an injection cylinder 13a having an injection port 13b, and the third injection device 14 includes 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 prevention member 17 is injected from the injection port 12b of the injection cylinder 12a. In the second injection device 13, when the lens 3 is formed by the 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 to which the wind noise/light leakage prevention member 17 is joined and the housing 2 are integrated by secondary injection, the integration resin 4 is injected from the injection port 13b of the injection tube 13a. Similarly, in the third injection device 14, when the lens 3 is formed by the primary injection, the resin for forming the lens 3 is injected from the injection port 14b of the injection cylinder 14a. On the other hand, when the lens 3 to which the wind noise/light leakage prevention member 17 is joined and the housing 2 are integrated by secondary injection, the integration resin 4 is injected from the injection port 14b of the injection cylinder 14a.

  In addition, in the injection molding device 30, movement control of the reciprocating rotation of the turntable 5 of 120° (first position control, second position control), the fourth mold 9, the fifth mold 10, the sixth mold. Control of approach/separation from/to the lower mold at the time of mold clamping/mold opening of 11 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, The injection control) is executed by the control unit 16 shown in FIG.

  As shown in FIGS. 1 and 2, a handling robot is arranged around the turntable 5 at appropriate intervals. For example, the first robot 19 and the second robot 20 are arranged at opposite positions around the turntable 5 and carry in/out the object to be processed (molded object) in each mold.

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

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

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

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

  That is, in the injection molding device 30 according to the present embodiment, the housing 2 and the wind noise/light leakage preventing member 17 are arranged at the first rotation position and the second rotation position of the turntable 5, respectively, and the first mold 6 and the fourth mold. The mold 9 or the second mold 7 and the fourth mold 9 are injection-molded 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 the third mold 8 and the sixth mold 11, and the inside of the third mold 8 and the fifth mold 10 or It is joined to the wind noise/light leakage prevention member 17 transferred to the inside of the third mold 8 and the sixth mold 11.

  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 that is molded by the injection molding device 30 shown in FIGS. 1 to 3 of the present embodiment, and is a resin molded product integrally molded with two or more kinds of resins. The lamp 1 mainly includes a lens (second member) 3, a housing (first member) 2 having a hollow structure, and an enclosed member such as a light bulb and a socket provided therein (see FIG. 15) 15. Consists of. The housing 2 and the lens 3 are made of different resins, and are integrated by the 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 wind noise/light leakage prevention member (third member) 17 is provided at the joint between the outer peripheral portion of the lens 3 and the housing 2. The housing 2 is made of non-translucent resin, the lens 3 is made of translucent resin, and the wind noise/light leakage preventing member 17 is made of non-translucent resin.

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

  Next, a method for manufacturing the injection-molded article of this embodiment will be described.

  As shown in FIG. 7A, on the turntable 5, each of the first die 6, the second die 7, and the third die 8 is 120° with respect to the rotation center C shown in FIG. Are arranged at intervals. In other words, they are arranged at 120° intervals along the rotation direction of the turntable 5. On the other hand, in order to correspond to the respective dies of the first die 6, the second die 7, and the third die 8, above the turntable 5, as shown in FIG. The mold 9, the fifth mold 10, and the sixth mold 11 are arranged.

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

  First, the first rotation position and the second rotation position, which are the positions at which the turntable 5 stops when performing reciprocating rotation and which performs a desired operation in each mold, will be described. The first rotation position and the second rotation position are positions at which the turntable 5 reciprocally rotates (turns) in a clockwise or counterclockwise direction and stops, and the respective molds perform processing such as injection molding. There is a positional relationship that forms an angle of 120° with the rotation center C of the turntable 5. For example, the rotation position of the turntable 5 shown in FIG. 1 is the above-mentioned first rotation position, and at each of A1, B1, and C1 positions set at intervals of 120° with respect to the rotation center C, desired positions are obtained. Processing such as injection molding is performed.

  Further, the position where the turntable 5 is rotated 120° counterclockwise or clockwise from the first rotation position is, for example, the second rotation position shown in FIG. 2. Also in the second rotation position, desired injection molding or the like is performed at each of the A1, B1, and C1 positions.

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

  After mold clamping, the first injection control is executed in step 2 of FIG. Specifically, at the position A1 in the state shown in FIG. 1 (first rotation position), the first mold 6 and the fourth mold 9 form the housing 2 which is the first member and the wind noise which is the third member. The light leakage prevention member 17 is formed (housing formation, wind noise/light leakage prevention member formation). The injection for molding the housing 2 and the wind noise/light leakage prevention member 17 in this step 2 is the 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 components. FIG. 12 shows the structure of the wind noise/light leakage prevention 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 prevention member 17 has a shape along the outer peripheral portion of the lens 3 as shown in FIG. 4, and is formed of the same resin material (non-translucent resin) as the housing 2. As described above, at the location A1 in step 2 of FIG. 5A, the housing 2 and the wind noise/light leakage prevention member 17 are in the same mold (first mold 6 and fourth mold 9) and are the same. Injection molding with the resin material. Preferably, the housing 2 and the wind noise/light leakage prevention member 17 are injection molded at the same time.

  In step 2, the lens 3 which is the second member shown in FIG. 13 is molded by the third mold 8 and the sixth mold 11 at the position C1 in the first rotation position shown in FIG. 1 (lens molding). ). The injection for molding the lens 3 in this step 2 is the 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 included in the third injection device 14. Further, after molding the lens 3, the wind noise/light leakage preventing member 17 is joined to the lens 3. That is, in step 10 of the first stage, the wind noise/light leakage preventing member 17 is moved and arranged by the first robot 19 inside the third mold 8 and the sixth mold 11 in advance. Then, by performing the primary injection by the third injection device 14, as shown in FIG. 13, the lens 3 is molded, and the wind noise/light leakage preventing member 17 is melted to cause wind noise to the outer peripheral portion of the lens 3. The light leakage prevention 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 resin material different from the housing 2.

  Further, in step 2, the second mold 7 and the fifth mold 10 are molded by the primary injection and the wind noise/light leakage prevention member 17 is joined at the position B1 in the first rotation position shown in FIG. Secondary injection is performed by the second injection device 13 that integrates the lens 3 and the housing 2. At that time, an integration resin (see FIG. 15) for integrally molding the housing 2 and the lens 3 is injected from an injection port 13b of an injection cylinder 13a included in the second injection device 13. At this time, the unifying resin 4 is injected to the abutting portion of 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 resin for integration 4 shown in FIG.

  In addition, in the series of operations performed by the injection molding apparatus 30, when the step 2 after the step 1 shown in FIG. 5A is the first cycle of the above-described series of operations, the housing molding and the lens molding of the preceding stage are performed. The process has not been performed, and the housing 2 and the lens 3 have not been molded yet. Therefore, only in the step 2 after the step 1 in the first cycle, the injection of the resin 4 for integration from the second injection device 13 for integrating the housing 2 and the lens 3 (the secondary Injection, secondary molding) is not performed, and the lamp 1 shown in FIG. 4 is not formed.

  As described above, the injection molding at each of 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 after Step 1 shown in FIG. 5A is the second cycle or later of the above-described series of operations, the lamp 1 is formed by the secondary injection of B1 position in Step 2.

  After the formation of the lamp 1 is completed, as shown in step 3 of FIG. 5A, the fourth mold, which is the upper mold of each mold, is located at each of the first rotation position A1, B1, and C1 of the turntable 5. The mold 9, the fifth mold 10, and the sixth mold 11 are moved to open the mold (state of FIG. 8B).

  After the mold is opened, in step 4 of FIG. 5A, the inner housing is assembled at the position A1 in the first rotation position of the turntable 5. Here, by the handling of the first robot 19 shown in FIG. 1, as shown in FIG. 16, an LED (light emitting diode) which is the sealing member 15 and a socket with a light bulb are arranged in the hollow portion 2a of the housing 2 (see FIG. State of b)).

  Further, at the position B1 in the first rotation position of the turntable 5, the finished product and the wind noise/light leakage prevention member are taken out by the robot. Here, by handling the first robot 19 shown in FIG. 1, the completed lamp 1 shown in FIG. 14 is taken out from the second mold 7 as shown in FIG. The handling noise 19 removes the wind noise/light leakage prevention member 17 shown in FIG. 12 from the fourth mold 9 as shown in FIG. 8B.

  Next, the control unit 16 executes the first position control in which the turntable 5 is turned counterclockwise by 120° 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 located at the second rotation position, the first die 6 serves as the sixth die 11 and the second die 7 serves as the fourth die 9 as shown in FIG. 8C. , The third mold 8 is arranged to face the fifth mold 10, respectively.

  After turning the turntable 5 by 120°, in step 5 of FIG. 5B, the wind noise/light leakage preventing member 17 is set by the robot at the position B1 in the second rotation position. Here, in step 4 at B1 position shown in FIG. 5A, the wind noise/light leakage preventing member 17 is taken out from the fourth die 9 shown in FIG. 6A by the first robot 19 shown in FIG. 6(b) and FIG. 8(c), the third mold 8 is moved (placed) inside (the cavity 18 shown in FIG. 7(a)).

  After the wind noise/light leakage prevention member 17 is moved, in step 6 of FIG. 5(b), the fourth mold, which is the upper mold of each mold, is located at each of A1, B1, and C1 in the second rotation position. 9, the fifth mold 10 and the sixth mold 11 are lowered to perform mold clamping (state of FIG. 9A).

  After the mold is clamped, the second injection control is executed by the controller 16 in step 7 of FIG. Specifically, at the location A1 in the second rotation position of the turntable 5, by the second mold 7 and the fourth mold 9, the housing 2 that is the first member and the wind noise/light leakage that is 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 prevention member 17 at the location A1 in step 7 is the primary injection by the first injection device 12. At that time, the 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 the wind noise/light leakage prevention member 17 shown in FIG. 12 is further molded. Resin for injection. That is, at step A1 in step 7, the housing 2 and the wind noise/light leakage prevention member 17 are injection-molded in the same mold (second mold 7 and fourth mold 9) and with the same resin material. .. Preferably, the housing 2 and the wind noise/light leakage prevention member 17 are injection molded at the same time. As shown in FIG. 10, the housing 2 is a member having a hollow portion 2a for mounting components.

  Further, in step 7, at the position B1 in the second rotation position, as shown in FIG. 9A, the third mold 8 and the fifth mold 10 are the second member, and the lens shown in FIG. 3 is molded (lens molding). The injection for molding 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 included in the second injection device 13. Further, after the lens 3 is molded, the wind noise/light leakage prevention member 17 is joined to the lens 3. That is, in step 5, since the wind noise/light leakage prevention member 17 is transferred to the inside of the third mold 8 by the first robot 19 in advance, the wind noise/light leakage to the lens 3 is performed together with the molding of the lens 3. The countermeasure member 17 can be joined. As shown in FIG. 13, for example, the wind noise/light leakage preventing member 17 is melted, and the wind noise/light leakage preventing 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 resin material different from the housing 2.

  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 included in the second injection device 13.

  Further, in step 7, at the position C1 in the second rotation position, as shown in FIG. 9A, the first mold 6 and the sixth mold 11 perform the primary injection of the housing 2 and the lens 3. Secondary injection (secondary molding) is performed by the third injection device 14 that integrates and. At that time, an integrating resin (see FIG. 15) for integrally molding the housing 2 and the lens 3 is injected from the injection port 14b of the injection cylinder 14a included in the third injection device 14. Specifically, the resin 4 for integration is injected to the abutting portion of the housing 2 and the lens 3. A wind noise/light leakage prevention member 17 is joined to the outer periphery of the lens 3. The molded body shown in FIG. 14 is a molded body (lamp 1) that is integrated (secondary molding) by secondary injection, and the lens 3 and the housing 2 are integrated via the resin for integration 4 shown in FIG. Has been converted. Further, in the lamp 1, a wind noise/light leakage prevention member 17 is provided at a joint portion of the lens 3 with the housing 2. This completes the manufacture of the lamp (injection molded body) 1 shown in FIG.

  After the manufacture of the lamp 1 is completed, as shown in step 8 of FIG. 5B, the fourth mold 9 which is the upper mold of each mold at each of the positions A1, B1 and C1 in the second rotation position, The molds are opened by raising the fifth mold 10 and the sixth mold 11 (state of FIG. 9B).

  After the mold is opened, in step 9 of FIG. 5B, the inner housing is assembled at the position A1 in the second rotation position. Here, as shown in FIG. 9B, the encapsulating member 15 is moved to the inside of the second mold 7 by the handling of the first robot 19 shown in FIG. Specifically, as shown in FIG. 16, a socket with a light bulb, which is the enclosing member 15, is arranged in the hollow portion 2 a of the housing 2.

  In step 9, the completed product and the wind noise/light leakage prevention member are taken out by the robot at the position C1 in the second rotation position. Here, by handling the first robot 19 shown in FIG. 1, the completed lamp 1 shown in FIG. 14 is taken out from the first mold 6 as shown in FIG. By handling 19 the wind noise/light leakage prevention member 17 shown in FIG. 12 is taken out from the fourth mold 9 as shown in FIG. 9B.

  Next, the control unit 16 executes a second position control in which the turntable 5 is turned clockwise by 120° from the second rotation position and stopped. That is, the turntable 5 is located at the first rotation position. When the turntable 5 is located at the first rotation position shown in FIG. 9C, the first mold 6 is the fourth mold 9, the second mold 7 is the fifth mold 10, and the third mold is the third mold. 8 are arranged so as to face the sixth mold 11, respectively.

  After turning the turntable 5, in step 10 shown in FIG. 5A, the wind noise/light leakage prevention member 17 is set by the robot at the position C1 in the first rotation position. Here, the wind noise/light leakage countermeasure member 17 is taken out from the fourth mold 9 shown in FIG. 6(a) by the first robot 19 shown in FIG. 1, and as shown in FIGS. 6(b) and 9(c). , And is moved (placed) inside the third mold 8 (cavity 18 shown in FIG. 7A).

  This is the end of the description of the one-cycle operation of assembling the lamp 1 at the first rotation position and the second rotation position of the turntable 5 in the injection molding device 30 of the present embodiment. In actual assembly, the operation of the injection molding apparatus 30 in one cycle is repeated a plurality of times to perform assembly.

  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 be used for the integral molding of two parts (in this embodiment, the housing 2 and the lens 3). Thus, it becomes possible to mold one member and the wind noise/light leakage prevention 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 by the same mold in the same step, and the lens 3 is injection-molded by another mold in the same step, the lens 3 It is possible to join the wind noise/light leakage prevention member 17 molded in the previous step. Thereby, the molding time of the lamp 1 can be shortened. Further, it is possible to improve the accuracy of injection molding in the lamp formation by the injection molding device 30.

  For example, after the secondary injection (secondary molding) in which two members are integrally molded, the wind noise/light leakage prevention member 17 is assembled in a separate process, the molded body after the secondary injection is finished by the manufacturing device. Since it is taken out from the mold once, there is variation in the product due to play during assembly and setting. However, in the injection molding device 30 of the present embodiment, when the lens 3 is molded in the lens molding process in the first stage of the integral molding, the wind noise/light leakage prevention member 17 is also joined to the lens 3 beforehand. Since the lens 3 to which the wind noise/light leakage prevention member 17 is joined and the housing 2 are integrally molded, the accuracy of injection molding when molding the lamp 1 can be improved.

  In addition, after the wind noise/light leakage prevention member 17 is molded, the robot transfers it to a lens molding die to mold the lens and join the wind noise/light leakage prevention member 17 to the lens 3, so that the injection is performed. It can be manufactured without removing it from the molding apparatus 30, and intermediate stock can be eliminated. When the wind noise/light leakage prevention member 17 is transferred to the lens molding die, the wind noise/light leakage prevention member 17 is arranged so as to match the respective directions of the lens 3 and the housing 2. Accordingly, when the wind noise/light leakage prevention 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 prevention member 17 or the lens 3 is newly formed. It is not necessary to change the direction, and the efficiency of injection molding can be improved.

  Furthermore, since the housing 2 and the wind noise/light leakage prevention member 17 are injection-molded by the same mold, the wind noise/light leakage prevention member 17 is not molded in a separate process, which reduces the number of workers and man-hours. Can be reduced. This makes it possible to reduce processing costs.

  Further, in the mold for molding the lens 3, since the wind noise/light leakage prevention member 17 is joined to the lens 3 in the same step as the lens molding, the housing 2 and the wind noise/light leakage prevention member 17 are injection-molded. Since the same mold is used, it is possible to reduce variations in the attachment of the wind noise/light leakage prevention member 17 and variations in the assembling of the lamp (injection molded body, resin molded product) 1. Thereby, the quality of the lamp 1 can be improved.

  It is needless to say that the present invention is not limited to the above-mentioned embodiment and can be variously modified without departing from the gist thereof. For example, in the above-described embodiment, the case where the mold opening (upper mold) and the mold closing are simultaneously performed by the control unit 16 has been described, but the fourth mold 9 and the fifth mold 10 that are upper molds are described. The sixth mold 11 may be controlled by the controller 16 so as to open and close the mold separately from each other.

  In the above embodiment, the case where the wind noise/light leakage prevention member 17 is taken out by the robot after the mold is opened after the secondary injection is explained. However, the wind noise/light leakage prevention member 17 is taken out from the inner housing. It may be performed after the assembling step.

  Further, 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-described embodiment, the angle formed by the first rotation position and the second rotation position, and the arrangement interval of the first mold 6, the second mold 7, and the third mold 8 (angle with respect to the rotation center C). However, the angles are not limited to 120° and may be angles other than 120°.

  Further, in the above-described embodiment, the case where each injection device includes one injection cylinder has been described, but each injection device may include a plurality of injection cylinders. For example, when the first injection device 12 includes two injection cylinders, different resins are injected from the respective injection cylinders to inject two members made of different resin materials in one mold. It becomes possible to mold.

1 lamp (injection molding, resin molding)
2 Housing (first member)
2a hollow part 3 lens (second member)
4 Resin for unification 5 Turntable 6 1st die 7 2nd die 8 3rd die 9 4th die 10 5th die 11 6th die 12 1st injection device 12a Injection cylinder 12b Injection port 13 2nd injection|emission apparatus 13a injection|emission cylinder 13b injection|emission opening 14 3rd injection|emission apparatus 14a injection|emission cylinder 14b injection|emission port 15 enclosing member 16 control part 17 wind noise/light leakage countermeasure member (3rd member)
18 Cavity 19 First Robot 20 Second Robot 30 Injection Molding Equipment

Claims (8)

Primary injection for injecting resin into the mold to mold the first, second and third members, and for joining the third member to the second member during molding of the second member; A device for manufacturing an injection-molded body, which performs secondary injection for injecting a resin into a second member to integrate the second member and the first member to which the third member is joined,
A turntable that reciprocates,
First, second and third molds arranged on the turntable at predetermined intervals along the rotation direction of the turntable;
Fourth, fifth and sixth molds which are mold opened and clamped with respect to the first, second and third molds;
First, second, and third injection devices for injecting resin into the mold that has been clamped,
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,
Have
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 first mold and the fourth mold face each other. The turntable rotates to a first rotation position where the 3rd mold and the 6th 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 first mold and the sixth mold face each other. The turntable rotates to a second rotation position where the 3rd mold and the 5th mold face each other,
When the control unit executes the first injection control subsequent to the first position control, the first injection is performed by the first injection device, and the first member in the first and fourth molds. And the third member is molded, the second injection is performed by the second injection device, and the second member and the first member are joined to the third member in the second and fifth molds. Are integrated, and the primary injection is performed by the third injection device to form the second member and join the third member to the second member in the third and sixth molds. Is done
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 in the second and fourth molds. And the third member is 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. Joining is performed, the second injection is performed by the third injection device, and the second member and the first member, to which the third member is joined in the first and sixth molds, An integrated injection molding device. The manufacturing apparatus of the injection-molded article according to claim 1,
The first, second and third molds are arranged at 120° intervals along the rotation direction of the turntable,
An apparatus for manufacturing an injection molded body, wherein the first rotation position and the second rotation position are positions that form an angle of 120° with respect to a rotation center of the turntable. Primary injection for injecting resin into the mold to mold the first, second and third members, and for joining the third member to the second member during molding of the second member; A method for manufacturing an injection-molded article, comprising: performing a secondary injection in which a resin is injected into the second member to integrate the second member and the first member to which the third member is joined,
A reciprocating turntable, first, second and third dies arranged on the turntable along the rotation direction of the turntable at predetermined intervals, and the first, second and third dies Fourth, fifth, and sixth molds that are opened and clamped with respect to the mold, first, second, and third injection devices that inject resin into the clamped molds, and the turntable A first position control and a second position control for the first and second and third injection devices, and a first injection control and a second injection control for the first, second and third injection devices, Preparing an apparatus for manufacturing 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 first mold and the fourth mold face each other. The turntable rotates to a first rotation position where the 3rd mold and the 6th 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 first mold and the sixth mold face each other. The turntable rotates to a second rotation position where the 3rd mold and the 5th mold face each other,
When the control unit executes the first injection control subsequent to the first position control, the first injection is performed by the first injection device, and the first member in the first and fourth molds. And the second member and the first member formed by molding the third member, performing the secondary injection by the second injection device, and joining the third member in the second and fifth molds. And the primary injection is performed by the third injection device to perform molding of the second member and joining of the third member to the second member in the third and sixth molds. Done,
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 in the second and fourth molds. And the third member is molded, the primary 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. And the second injection is performed by the third injection device, and the second member and the first member, to which the third member is joined in the first and sixth molds, are integrated. A method for producing an injection-molded article. The method for manufacturing an injection-molded article according to claim 3,
The first, second and third molds are arranged at 120° intervals along the rotation direction of the turntable,
A method for manufacturing an injection-molded article, comprising reciprocatingly moving the turntable at the first rotation position and the second rotation position forming an angle of 120° with respect to the rotation center of the turntable. 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 arranged in advance in the mold. Production method. 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 moved to the third and fifth molds. The mold is moved to the inside of the mold or the third and sixth molds, and the third member is arranged inside the third and fifth molds or the inside of the third and sixth molds. A method for 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. The method for producing an injection-molded article according to claim 3, 4, 5, or 6,
A method for manufacturing an injection-molded article, wherein the first member and the third member are injection-molded in the same step and with the same resin material in the same mold. A resin molded product formed by the method for producing an injection molded body according to claim 3,
A housing as the first member made of a non-translucent resin;
A lens as the second member made of a translucent oil tree,
A wind noise/light leakage prevention member as the third member, which is made of a non-translucent resin;
Have
The wind noise/light leakage preventing member is a resin molded product provided along the outer peripheral portion of the lens.

Images