Patent Application
20230093625
The present disclosure relates to an injection molding system for manufacturing positive chip components.
Current manufacturing of a molded part by an injection molding system includes clamping a mold, injecting a resin into the mold, pushing the resin into the mold at high pressure to compensate for volume reduction caused by solidification of the resin, securing the molded part in the mold until the resin solidifies, and removing the molded part from the mold. Each of these injection molding steps is repeated as needed.
After performing a molding process a predetermined number of molds with a mold, the molds are unloaded from the injection molding machine. A changeover for a new mold is performed, and the new mold is inserted into the injection molding system. The new mold is then used for a predetermined number of injection molding cycles. This process can often take time and resources, and typically the injection molding system remains in a standby state during this process. This can impact overall productivity. In addition, since molds are typically heavy and heated during use, it is necessary to consider operator safety.
In order to increase productivity, a method using two molds per injection molding system has been proposed. For example, Japanese Patent Publication No. 6121601 describes a system in which two conveying devices independent of an injection molding machine are arranged on both sides of the injection molding machine. In this system, a molded part is manufactured while multiple molds are replaced by a conveying device for one injection molding machine. The conveying device used in the injection molding system of Japanese Patent Publication No. 6121601 includes independent drive sources for each mold and a controller independent from the injection molding machine, which complicates the system.
According to an aspects of the present disclosure, an injection molding system includes an injection nozzle that injects a resin into a mold and an actuator that controls conveying at least one mold, wherein an improvement of the injection molding system includes the actuator driving a support member that supports a mold, wherein the mold is conveyed, based on a movement of the support member, between a first position where the injection nozzle injects the resin and a second position that is different from the first position.
The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments, objects, features, and advantages of the present disclosure.
Throughout the Figures, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components or portions of the illustrated embodiments. While the subject disclosure is described in detail with reference to the Figures, it is done so in connection with the illustrative exemplary embodiments. It is intended that changes and modifications can be made to the described exemplary embodiments without departing from the true scope and spirit of the subject disclosure as defined by the appended claims.
An injection molding system according to an exemplary embodiment will be described with reference to the drawings. In each of the drawings, arrows X and Y denote horizontal axis directions orthogonal to each other, and arrows Z denote vertical axis directions.
An operation of the injection molding system 1 according to an exemplary embodiment will be described in detail below with reference to
The injection molding system 1 includes an injection unit 4 including an injection nozzle 2 and an injection cylinder 3 and performs an injection process by moving the mold A 5 and the mold B 6. When the resin is injected, the mold is fixed by the platen 7. A changing/moving operation of the mold is performed via a support member (chain conveyor 8) that is moved by an actuator 15.
In the present exemplary embodiment, the support member is a member that supports a mold into which a resin is injected by an injection molding machine from below in the vertical-axis direction. In the present exemplary embodiment, a processor (not illustrated) controls operation of the injection unit 4, setting and control of a plasticizing condition and the injection condition of the resin, control of a cooling time, and movement control of the mold by the support member. This simplifies the molding system compared to implementing multiple processors. In another exemplary embodiment, some of the above-described processes can be executed by different processors.
Turning to
Plasticization conditions and injection conditions of the resin to the mold A 5 are executed under a preset condition A. For example, preset condition A can include setting a resin temperature, an injection filling speed, and a packing pressure so that a flowability of resin can be secured in a mold.
After the cooling time counting begins, in step S105, clamping of the mold A 5 by the platen 7 is released at a predetermined time after the cooling time counting starts and the chain conveyor 8 is operated. In step S107, the mold A 5 and the mold B 6 are conveyed in a negative X-axis direction (
During the above-described process, the plasticizing condition and the injection condition of the resin set in the injection unit 4 are changed from the preset condition A to a preset condition B. Preset conditions A and B can either be the same condition or different conditions. In step S111, resin melted and mixed under preset condition B is injected into the mold B 6 fixed to the platen 7. A cooling time counting for the mod B 6 is then started.
In step S113, after the cooling time counting is started, clamping of the mold B 6 by the platen 7 is released at a predetermined time after the cooling time counting starts. In step S115, the mold A 5 and the mold B 6 are conveyed in a positive X-axis direction (
In step S117, when the cooling time for the mold A 5 elapses, the mold A 5 is opened by a mold opening operation of the platen 7, and a resin molded part A (not illustrated) in the mold A 5 is removed. Next, in step S119, a determination is made whether the number of resin molded parts produced by the mold A 5 has reached a predetermined number. If the predetermined number is reached, flow proceeds to step S121. In step S121, the mold A 5 is replaced with another mold. If the predetermined number has not been reached, flow proceeds to step S123.
In step S123, the mold A 5 is closed by the mold clamping operation of the platen 7 after the resin molded parts (not illustrated) are removed. Then, in step S125, resin melted under the pre-set condition A is injected.
Next, in step S127, after the cooling time counting begins, clamping of the mold A 5 by the platen 7 is released at a predetermined time after the cooling time counting started. In step S129, the chain conveyor 8 is operated to move the mold A 5 and the mold B 6 in a negative X-axis direction (
In step S133, it is determined whether the number of the resin molded parts B produced by the mold B6 has reached a predetermined number. If it is determined that the predetermined number has been reached, the flow proceeds to step S135. In step S135, the mold B 6 is replaced with another mold. If it is determined that the predetermined number has not been reached, the flow proceeds to step S137.
In step S137, the mold B 6 is closed by the mold clamping operation of the platen 7 after the resin molded parts B are removed. Then, in step S139, melted resin is injected based on the preset condition B.
In step S141, after the cooling time counting begins, clamping of the mold B 6 by the platen 7 is released at a predetermined time after the cooling time counting started., In step S143, the chain conveyor 8 is operated to move the mold A 5 and the mold B 6 in a negative X-axis direction (
In the above-described process, when the support member repeatedly conveys a mold in the X-axis direction, injection and cooling of the mold A 5 and the mold B 6 and removal of the molded parts are repeated. In the present exemplary embodiment, operation of the support member is accomplished via an operation panel (not illustrated) for setting a resin plasticizing condition or an injection molding condition of the injection molding system 1. However, this is not seen to be a limiting implementation, and any method that would enable operation of the support member is applicable.
Returning to
In the present exemplary embodiment, the injection molding system 1 of
The support member is not limited to the chain conveyor 8.
Providing the injection molding system 1 with a mold carrying in/out function, such as a chain conveyor 8, a belt conveyor 9, an expansion conveyor 10, or a slide conveyor 11, a seamless state is formed between the first position and the second position, and a mold can be smoothly carried in/out. The above-described conveyors are all motorized. However, these are not seen to be limiting, and any conveying mechanism that would enable practice of the present disclosure is applicable.
The support member (chain conveyor 8, belt conveyor 9, expansion conveyor 10, or slide conveyor 11) in
The movement amount of the support member (chain conveyor 8, belt conveyor 9, expansion conveyor 10, or slide conveyor 11) is detected by a movement sensor (not illustrated). The actuator 15 stops moving the support member based on a detection result of the moving amount detected by the moving sensor. Thus, conveyance of a mold can be based on a predetermined conveying amount. The movement sensor can also detect an amount of mold conveyance instead of the amount of support member conveyance, which can be used to control operation of the actuator 15.
The injection molding system 1 also includes a position sensor (not illustrated) that detects the position of a mold. The actuator 15 stops moving the support member based on a detection result of the position of a mold by the position sensor. Using the position sensor to control the actuator 15 enables preventing damage, for example, due to a mold colliding with a support member even if there is an erroneous input of the moving amount of the support member or an erroneous detection of the moving amount by the moving sensor.
The actuator 15 includes a force sensor (not illustrated) that detects a magnitude of force provided to the support member (chain conveyor 8, belt conveyor 9, expansion conveyor 10, or slide conveyor 11). Operation of the actuator 15 can be controlled based on a detection result by the force sensor. This enables preventing the support member from stopping and avoiding any damage in the event that a foreign matter interferes with the normal operation of the support member.
As illustrated in
The end wall 17 and the end wall 18 are doors that can be opened and closed, and can be locked to prevent them from opening during an injection molding process. When the mold A5 is replaced in step S121 of
In the present embodiment, both end wall 17 and end wall 18 are automatically locked and unlocked. More specifically, when it is determined in step S119 of
If it is determined in step S133 of
In the present embodiment, the end wall 17 and end wall 18 are locked and unlocked by the injection molding systems 1 processor (not illustrated).. In another exemplary embodiment, the end wall 17 and the end wall 18 can, for example, be locked by a magnet. Any method of locking and unlocking the end wall 17 and the end wall 18 that would enable practice of the present disclosure is applicable.
The configuration of
The end wall 18 and the side wall 19 can open and close as in
The above-described exemplary embodiments have described the carrying in/out directions of the mold A 5 and the mold B 6 as being in the X-axis direction. They carrying in/out direction is not limited to the X-axis direction. In another exemplary embodiment, the direction can be in the Z-axis direction.
In
In general, the steps of
In the present embodiment, the configuration of the electric lifter 12 results in conveyance of the mold A 5 and the mold B 6 in a positive Z-axis direction in step S107 of
In the present embodiment, the configuration of the electric lifter 12 results in conveyance of the mold B6 in a negative Z-axis direction in step S115 of
In the present embodiment, the configuration of the electric lifter 12 results in conveyance of the mold A 5 in a positive Z-axis direction in step S129 of
In the present embodiment, the configuration of the electric lifter 12 results in conveyance of the mold B 6 in a negative Z-axis direction in step S143 of
In the present embodiment, when the electric lifter 12 repeatedly conveys a mold in a Z-axis direction, injection and cooling of the mold A 5 and the mold B 6 and removal of a resin molded part is repeated.
As illustrated in
In referring to the description, specific details are set forth in order to provide a thorough understanding of the examples disclosed. In other instances, well-known methods, procedures, components and circuits have not been described in detail as not to unnecessarily lengthen the present disclosure.
It should be understood that if an element or part is referred herein as being “on”, “against”, “connected to”, or “coupled to” another element or part, then it can be directly on, against, connected or coupled to the other element or part, or intervening elements or parts may be present. In contrast, if an element is referred to as being “directly on”, “directly connected to”, or “directly coupled to” another element or part, then there are no intervening elements or parts present. When used, term “and/or”, includes any and all combinations of one or more of the associated listed items, if so provided.
Spatially relative terms, such as “under” “beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the various figures. It should be understood, however, that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, a relative spatial term such as “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein are to be interpreted accordingly. Similarly, the relative spatial terms “proximal” and “distal” may also be interchangeable, where applicable.
The term “about,” as used herein means, for example, within 10%, within 5%, or less. In some embodiments, the term “about” may mean within measurement error.
The terms first, second, third, etc. may be used herein to describe various elements, components, regions, parts and/or sections. It should be understood that these elements, components, regions, parts and/or sections should not be limited by these terms. These terms have been used only to distinguish one element, component, region, part, or section from another region, part, or section. Thus, a first element, component, region, part, or section discussed below could be termed a second element, component, region, part, or section without departing from the teachings herein.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “includes”, “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Specifically, these terms, when used in the present specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof not explicitly stated. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. For example, if the range 10-15 is disclosed, then 11, 12, 13, and 14 are also disclosed. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.
It will be appreciated that the methods and compositions of the instant disclosure can be incorporated in the form of a variety of embodiments, only a few of which are disclosed herein. Variations of those embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the disclosure to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
