JP3391740B2 - Manufacturing apparatus and manufacturing method for insert molded product - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an insert-molded article manufacturing apparatus and an insert-molded article manufacturing method using such an apparatus.

[0002]

2. Description of the Related Art Conventionally, as a method for manufacturing a part or member by covering the outside of a reinforcing core material such as metal with a synthetic resin, the core material is placed in a molding die in advance and then the molding die is closed. In general, the so-called insert molding method, in which the molded product in which the predetermined surface area or the whole of the core material is covered with synthetic resin is obtained by clamping the mold and filling the molding cavity with molten resin, is generally good. Are known. According to this insert molding method, since the coating resin is integrally molded on the outer peripheral portion of the core material, the number of parts is increased as compared with the case where the coating resin portion is separately molded and attached to the outer peripheral portion of the core material. Can be suppressed, the labor for assembling the both is unnecessary, and the adhesion between the both can be enhanced.

[0003]

However, in this insert molding method, when the core material is insert-fixed in the molding die or when the work is taken out from the molding die after molding, the core material (that is, the molding product) is removed. Depending on the size and shape, it becomes difficult to handle the core material or the molded product, and it becomes difficult to stably obtain good results regarding the shape accuracy of the molded product and the adhesion of the coating resin to the surface of the core material. . Further, in this case, since it is difficult to handle the core material or the molded product, it is very disadvantageous in improving productivity.

That is, for example, a so-called "long product" whose length is very long compared to its cross-sectional size, and whose outside is covered with resin (for example, a roof rack arranged on the vehicle roof). If this insert molding method is applied to, the core material is likely to be bent or deformed due to a fixing force when inserting and fixing the core material into the molding space of the mold or a resin injection filling pressure. If the resin skin is formed in a state where the core material is bent or deformed as described above, the shape accuracy of the molded product may be impaired, and the adhesion of the resin skin to the surface of the core material may be adversely affected. . Further, even when the work is taken out from the mold after molding, the core material is likely to be bent or deformed, and similar problems may occur with respect to the shape accuracy of the molded product and the adhesion of the resin skin. Furthermore, in the case of such a flexible long product (particularly when the weight is heavy), it is difficult to handle the product, and it is difficult to secure good productivity.

The present invention has been made in view of the above problems, and when manufacturing an insert-molded article, the bending of the core material occurs when the core material is inserted into the molding die or when the work is taken out from the molding die. And deformation can be suppressed,
Moreover, it aims at providing the manufacturing method and apparatus which can aim at improvement of productivity.

[0006]

Therefore, the manufacturing apparatus according to the invention of claim 1 of the present application (hereinafter, referred to as the first invention of the present application) is formed by previously incorporating a core material in a forming die. A manufacturing apparatus used for manufacturing an insert-molded product in which a predetermined surface region or the whole of the core material is covered with a synthetic resin by filling a molten resin in a cavity,
A work base is provided for performing a nesting operation of assembling a nest fitted at a predetermined location in the molding die at a predetermined location of the core material, and a nest removal work for removing the nest from the core material of the molding work, A first clamp mechanism capable of gripping a core material via the nest, a second clamp mechanism capable of gripping a molding work via the nest, a front of a molding die in which these clamp mechanisms are incorporated into the nest, and the work base. Mechanism for reciprocating between the front and the rear of the mold, an advance / retreat mechanism for advancing / retreating the clamp mechanism with respect to the mold and the work base, the advance / retreat mechanism, the move mechanism, and the clamp mechanism. And a control means for driving and controlling the
The clamp mechanism, after gripping the core material via the insert on the work base, fits the insert into a predetermined position in the mold to incorporate the core into the mold, The two-clamping mechanism grasps the forming work in the forming die through the insert, removes the forming insert from a predetermined position of the forming die, and removes the forming work from the forming die. It is characterized in that each of the clamp mechanisms is drive-controlled so as to be set on the front surface of the work base.

The invention according to claim 2 of the present application (hereinafter,
The second invention of the present application. ), In the first aspect of the invention, the molding die is provided with an eject mechanism for ejecting a molding work through the nest after the mold is opened, while the support base supporting the second clamp mechanism is provided with the nest of the nest. A pressing mechanism for applying a pressing force to the nest is provided opposite to the ejecting operation, and the pressing force by the pressing mechanism is set to be smaller than the ejecting force of the eject mechanism.

The invention according to claim 3 of the present application (hereinafter,
It is called the third invention of the present application. ), In the first or second aspect of the invention, the support base for supporting the first clamp mechanism is provided with an engagement mechanism capable of engaging the support base with a molding die. When the insert clamped by the first clamp mechanism is fitted into a predetermined position in the molding die to incorporate the core into the molding die, the support mechanism is previously attached to the molding die by the engagement mechanism. It is characterized in that, after being engaged with each other, a fitting force for fitting the insert into a predetermined position in the mold is applied.

Furthermore, the invention according to claim 4 of the present application (hereinafter, referred to as the fourth invention of the present application) is the same as the first clamp mechanism and the second clamp mechanism according to any one of the first to third inventions. The clamp mechanism is supported by a common support base at a predetermined distance, and the control means controls the common support base at a pitch equal to the predetermined distance in front of the work base or in front of the mold. It is characterized in that it can be controlled to move.

Furthermore, the invention according to claim 5 of the present application (hereinafter, referred to as the fifth invention of the present application) is the insert molded article according to any one of the first to fourth inventions,
A roof rack for a vehicle, comprising a rack body extending in a vehicle body front-rear direction on an upper side of a vehicle roof, and a mounting portion to the vehicle body roof, the mounting portion and the outside of the rack body being covered with a synthetic resin. It was done.

Further, in the manufacturing method according to the invention of claim 6 of the present application (hereinafter referred to as the sixth invention of the present application), the core material is previously incorporated in the molding die, and the molten resin is filled in the molding cavity. A method for manufacturing an insert-molded article in which a predetermined surface region of the core material or the whole is covered with a synthetic resin, and a nest fitted at a predetermined position in the molding die is provided in the core material. Nesting step of assembling to the part, first clamping step of gripping the core material arranged on the work base through the nest by the first clamping mechanism, and unclamping of the molded work gripped by the second clamping mechanism. And a work set step of setting the front surface of the work base, and a step of removing the nest from the molding work set on the front surface of the work base. A first moving step of moving the pump mechanism from the front of the work base to the front of the mold in which the nest is incorporated; a first positioning step of positioning the second clamp mechanism with respect to the mold; A second clamping step of gripping the molding work of the previous cycle in the molding die through the nest by the two-clamping mechanism;
By removing the insert gripped by the clamp mechanism from a predetermined position in the mold, a work taking-out step of taking out the molded work of the previous cycle from the mold, and moving the second clamp mechanism by a predetermined amount. First above
A second positioning step of positioning the clamp mechanism with respect to the molding die, and fitting the nest held by the first clamp mechanism into a predetermined position in the molding die to move the core material into the molding die. And a second moving step of moving the first and second clamp mechanisms from the front of the mold to the front of the work base.

The invention according to claim 7 of the present application (hereinafter,
It is called the seventh invention of the present application. ), In the sixth invention, when the forming work in the forming die is held by the second clamp mechanism, the ejecting mechanism provided in the forming die protrudes the forming work through the nest. The mold work is gripped through the insert while the pressing force that opposes the protruding force and is smaller than the pressing force is applied to the insert.

Furthermore, the invention according to claim 8 of the present application (hereinafter referred to as the eighth invention of the present application) is the sixth or seventh invention, wherein the insert clamped by the first clamp mechanism is formed. When fitting at a predetermined location in the mold, the nest is fitted at a predetermined location in the molding die while the support base supporting the first clamp mechanism is engaged with the molding die. It is characterized by exerting a fitting force.

Furthermore, the invention according to claim 9 of the present application (hereinafter, referred to as the ninth invention of the present application) is the insert molded article according to any one of the sixth to eighth inventions,
A roof rack for a vehicle, comprising a rack body extending in a vehicle body front-rear direction on an upper side of a vehicle roof, and a mounting portion to the vehicle body roof, the mounting portion and the outside of the rack body being covered with a synthetic resin. It was done.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a case in which an embodiment of the present invention is applied to, for example, manufacturing a roof rack of an automobile will be described in detail with reference to the accompanying drawings. Figure 1
FIG. 1 is an overall perspective view of a vehicle 1 equipped with a roof rack 10 according to this embodiment. As shown in this figure, the roof racks 10 are provided in a pair on the left and right on the upper side of the vehicle body roof 2. For example, taking the right side as an example, as will be understood from FIGS. A rack body 11 extending in the front-rear direction and a vehicle body roof 2
And a plurality of legs 12, 13 and 14 for attachment to the outer cover, and the outside is covered with a synthetic resin skin.

As shown in FIG. 4, the rack body 11 is provided with a core 16 made of, for example, a steel pipe therein, and the mounting legs 12, 13, 14 are formed by bending a steel plate, for example. The mounting brackets 17, 18, and 19 are formed respectively, and these mounting brackets 17, 18, 19 are provided.
Are integrally fixed to the core 16 by welding, for example. In this way, the core member assembly 15 is formed by fixing the mounting brackets 17, 18, and 19 to predetermined portions of the metal core member 16. Then, the roof rack 10 is formed by covering the outside of the core material assembly 15 with a skin of a predetermined synthetic resin. Incidentally, FIG.
Although not specifically shown in Fig. 3, mounting bolts are fixed to the bottoms of the respective mounting brackets 17, 18 and 19 after inserting the respective holes 17h, 18h and 19h, as will be described later. ing.

In the present embodiment, the mounting brackets 17, 18, 1
9 is integrally fixed to the outside of the core 16 (that is,
When the outer surface of the core material assembly 15 was covered with a synthetic resin skin, resin molding was performed by an insert molding method so that the coating resin and the insert material (core material assembly 15) were integrated. That is, the core material assembly 15 is insert-fixed at a predetermined position in a molding die to perform mold clamping, and a molten resin is injected and filled in a molding space in which the insert material is held, for example, by an injection molding method. Molded. Since the insert molding method is basically the same as a well-known method, detailed description and illustration of the method itself are omitted.

More preferably, as shown by an imaginary line arrow G in FIG. 2, gates are provided so as to face each other in the mold portions corresponding to the left and right sides of the central mounting leg portion 13, respectively. Molten resin is injected and filled from the gate. Therefore, the injection pressure of the molten resin is applied substantially evenly from the left and right to the portion of the core material 16 where the mounting bracket 18 is fixed at the central portion thereof and the rigidity thereof is relatively high. Material 16
The deformation of can be minimized. Further, more preferably, as shown in FIG. 5, the basic cross section of the roof rack 10 is set to be bilaterally symmetrical. As a result, the amounts of the molten resin filled from the left and right sides of the central mounting leg portion 13 are substantially equalized, and it is possible to suppress the decrease in strength at the so-called weld portion where the molten resins collide with each other.

In this embodiment, the insert material 15 is used.
Fixing (the above-mentioned core material 16 and mounting metal fittings 17, 18, 19: that is, the core material assembly) to the molding die is performed by mounting each mounting metal fitting 17, 1
I did it using 8,19. That is, when performing the insert molding, the mounting leg portion 12 of the molding die,
For the parts corresponding to 13 and 14, so-called nesting was used. This nesting will be described, for example, with respect to the mounting leg portion 12 on the front side, as shown in FIGS. 6 to 8, the main body portion 21 formed in a substantially rectangular parallelepiped shape, and protruding from the main body portion 21. Provided and core material 16
A pair of parallel protrusions 22 extending along the longitudinal direction of
A groove 23 is formed between the pair of parallel protrusions 22 to receive the corresponding mounting member 17, and an intermediate protrusion 24 provided at a substantially intermediate position of the groove 23.

By inserting the fittings 17, 17 into the groove 23 so as to sandwich the intermediate protrusion 22, and fixing the fittings 17, 17 to the main body 21, the core 16 is inserted into the insert 20. Fixed. As can be seen from FIG. 6, the side surface of the insert body 21 has a lock pin (described later) that engages the engaging recess 21a with which a clamper claw portion of a later-described clamp device can be engaged and the insert 20 with a molding die. The taper hole 21c into which is inserted is formed.

A mounting bolt 31 is fixed to the bottom portion 17b of each of the mounting brackets 17 by, for example, spot welding after inserting the hole portion 17h into the bottom portion 17b. Recesses 25 that receive the mounting bolts 31 are formed at the portions corresponding to the mounting bolts 31.
The groove receiving surface 23f of the insert 20 is provided with a bolt insertion hole 23h into which the mounting bolt 31 is inserted. The work of fixing the mounting bolt 31 to the bottom 17b of the fitting may be performed either before or after the work of assembling the core assembly 15, but in the present embodiment, the work is easy. From the core material assembly 15 before assembly.

The receiving surface 23f of the groove 23 is brought into contact with the bottom surface 17f of the mounting member 17 so that each mounting member 17 can be in contact with the bottom surface 17f.
Each of the mounting bolts 31 protruding from the bottom portion 17b of each mounting bracket 17 while being assembled in the groove 23 of the insert 20.
Are inserted into the bolt insertion holes 23h, and nuts 29 (see phantom lines in FIGS. 7 and 8) are screwed into the mounting bolts 31 in the corresponding recesses 25, and the nuts 29 are respectively tightened. The insert 20 is fastened and fixed to the mounting bracket 17 with the groove receiving surface 23f of the insert 20 being in contact with and in close contact with the bottom surface 17f of the mounting bracket 17. The work of fixing the nest 20 corresponds to the "nesting assembly step" described in the claims of the present application. As described above, by fastening and fixing the nest 20 to the mounting bracket 17 with the mounting bolts 31 and the nuts 29, the nest 20 can be simply and reliably fixed to the mounting bracket 17, and the nest 20 can be fixed after resin molding. It can be removed from the mounting bracket 17.

As can be seen from FIGS. 7 and 8, the nest 20 is fitted and fixed to a predetermined portion of either one of the pair of molding dies M1 and M2 (in this embodiment, for example, the molding die M1). It That is, the nest 20 is fixed to the molding die М1 by fitting the main body portion 21 into the nesting recess J1 formed at a predetermined portion of the molding die М1. still,
As for the other mounting legs 13 and 14, a nest having basically the same structure as that of the mounting leg 12 on the front side is used. Therefore, the insert material 15 (the core material assembly in which the mounting members 17, 18, and 19 are fixed to the core material 16) is fixed to the molding die M1 through the nests 20.

That is, since the fixing force when the core material assembly 15 is insert-fixed in the molding die М1 is received by each of the nests 20, this fixing force directly acts on the elongated core material 16. As compared with the case, the metal core material 16 of the roof rack body 11 is unlikely to bend or deform, and even if it occurs, the degree thereof is extremely small. And the mold М
1 and М 2 are closed and mold-clamped, and then a predetermined synthetic resin is injected and filled in a molten state into the molding space MC in which the insert material 15 (core material assembly) is held. 11 and legs for mounting on the vehicle body 12,13,1
The roof rack 10 is obtained by integrally forming the cover resin 30 and the coating resin 30 that covers the outside thereof.

As a result, the number of parts when the roof rack 10 is assembled to the vehicle body roof 2 can be minimized, and the vehicle assembling process (roof rack assembling process) and the parts management can be simplified. Moreover, since the core assembly 15 is insert-fixed in the molding die М1 via the insert 20, even if the core 16 is a considerably long product,
It is possible to effectively prevent the core material 16 from being bent or deformed by the fixing force when the core material assembly 15 is inserted and fixed.

In the present embodiment, it is preferable that there is a difference in shrinkage between the insert material (the core material 16 to which the fittings 17, 18, 19 are integrally fixed) and the coating resin 30. In order to effectively prevent shrinkage cracking at the time of solidification due to this, as a resin material to be injected and filled, for example, a length of 6 to
A polypropylene (PP) resin containing, for example, 5 to 40% by weight, and more preferably 10% by weight, of a glass reinforcing fiber of 13 mm long fiber is used.

As shown in FIG. 9, the roof rack 10 as an integral product thus obtained has a ring-shaped seal packing 32 and a substantially rectangular protector 33 on each of the mounting leg portions 12, 13, 14 as shown in FIG. Each of them is attached, and a cap member 34 is adhered and fixed to an intermediate portion of the rack body 11 and then assembled to the vehicle body roof 2. Each mounting leg 1
When fixing 2, 13, 14 to the vehicle body roof 2, for example, as shown in FIGS. 10 and 11, taking the case of the front side mounting leg 12 as an example, a concave shape provided on the roof panel 3 of the vehicle body roof 2 is used. Each mounting leg portion 12 is located in the groove portion 4 and the ring-shaped seal packing 32 surrounding the mounting bolt 31 is provided between the bottom portion 17b of the mounting bracket 17 and the bottom surface 4b of the groove portion 4 of the roof panel 3. The mounting bolt 31 is installed between the bottom end surface of the coating resin 30 and the top surface of the roof panel 3 with a protector 33 for sealing between them and protecting the surface of the panel 3. A nut 35 is inserted into a hole 4h provided in the groove bottom surface 4b, and a nut 35 is screwed to the mounting bolt 31 from the lower surface side of the roof panel 3 so as to be fastened and fixed.

In the above example, the mounting brackets 17, 18 and 1
9 is formed by bending a steel plate material by pressing or the like. For example, when the front side 17 is described as an example, a bottom portion 17b substantially along the longitudinal axis of the core material 16 of the roof rack 10 and the bottom portion 17b. And a pair of vertical wall portions extending upward from the pair of vertical wall portions are formed in a substantially U-shape in a side view, and the upper end of the pair of vertical wall portions is joined to the core member 16 to attach the mounting bracket 17 to the core. It was fixed to the material 16 (see, for example, FIGS. 4, 8 and 11). Instead of this, as shown in FIG. 12, the bottom portion 47b and the core member 1
As an additional vertical wall in addition to the pair of vertical walls 47a for connecting 6 and 6, a third vertical wall portion 47w may be provided so as to stand upright from the bottom portion 47b. By additionally providing such a third vertical wall portion 47w, the strength and rigidity of the mounting bracket 47 can be improved, and the supporting rigidity and mounting strength of the roof rack can be increased.

In this embodiment, when the above-mentioned insert molding is performed, the core material assembly 15 is incorporated into the molding die М1, and the insert-molded work (roof rack 10) is taken out from the molding die М1. A handling device for insert molding is used to handle the core assembly 15 and the molded work 10. The handling device will be described below. 13 is a side view schematically showing the overall configuration of the handling device 50 according to the present embodiment, and FIG. 14 is Y14-Y in FIG.
14 is a view from the direction of arrow, and FIG. 15 is a view from the direction of Y15-Y15 in FIG.

As shown in these figures, the handling device 50 includes a base frame 51 formed by combining a large number of steel materials and steel plate members each having a L-shaped or U-shaped longitudinal section, and the base frame 51. Clamp devices (first and second clamp devices CL1 and CL2) arranged at both ends in the longitudinal direction of the. Incidentally, these first clamp device CL1 and second clamp device C
L2 corresponds to the “first clamp mechanism” and the “second clamp mechanism” described in the claims of the present application, respectively, and the base frame 51 that supports the first and second clamp devices CL1 and CL2 is the present application. It corresponds to the "support base" described in the claims.

In the present embodiment, more preferably, the above-mentioned molds М1 and М2 have two molds in one molding cycle so that one set of left and right roof racks 10 can be molded in one molding cycle. It is of a so-called two-piece type, in which a molded product is obtained. The clamp devices CL1 and CL2 are provided at the respective end portions of the base frame 51,
Two each, that is, one first clamping device CL1
If the second clamp device CL2 and the second clamp device CL2 form one set, two sets of clamp devices (CL1 + CL2) are arranged side by side in the horizontal direction. The molding molds М1 and М2 are, for example, horizontal type (horizontal type) arranged in pairs so as to be opened and closed in the left-right direction (horizontal direction). Instead of this, a pair of vertical type (vertical type) molds that are arranged to be openable and closable in the vertical direction may be used.

The base frame 51 is a vertical frame 52 (5 having an L-shaped cross section extending parallel to each other in the longitudinal direction).
2A, 52B) and a horizontal frame 53 (53A to 53C) having an L-shaped cross-section and arranged in a direction orthogonal to the vertical frame 52 so as to bridge the vertical frames 52. The vertical frame 52 has two sets (a total of four) of the frame 52A and the frame 52B as one set, and the horizontal frame 53 has two sets (a total of six) of the frames 53A to 53C as a set symmetrically. , Respectively. An arm fixing plate 55 for fixing a moving arm 71 that moves and rotates the entire base frame 51 is provided above the center steel plate 54 arranged substantially in the center of the base frame 51 in the longitudinal direction. A plate member 56, to which the upper ends of a plurality of (four) stopper cylinders 72 are fixed, is located outside the arm fixing plate 55.

In each of the first horizontal frames 53A located at the longitudinal ends of the base frame 51, the upper portions of the two pin members (positioning pins) 73 are, for example, via shaft holders 73a (see FIG. 20). It is fixed. The positioning pins 73 are used to accurately position the base frame 51 with respect to the molding die М1 to which the core assembly 15 is insert-fixed, and the base frame 51 with respect to the work table of the nesting station described later. is there. As shown in FIG. 20, the molding die М1
Positioning holes 63 are respectively provided at a plurality of positions of the base frame 5 according to the forward movement of the moving arm 71.
1 moves forward to the molding die М1 side, and the tip end of each positioning pin 73 is fitted into the corresponding positioning hole 63, whereby the base frame 51 is accurately positioned with respect to the molding die М1.

On the lower surface side of each second horizontal frame 53B, when the core material assembly 15 is assembled in the molding die М1,
A lock device 74 including an engagement hook 76 that engages the base frame 51 with the mold М1 and a pneumatic cylinder 75 that drives the engagement hook 76 is attached. As shown in FIG. 21, there are engaging recesses 64 having engaged portions 64a capable of engaging with the engaging hooks 76 at a plurality of locations on the molding die М1, and the core material assembly 15 is formed on the molding die М1. When assembled inside, the base frame 51 advances to the forming mold М1 side in accordance with the forward movement operation of the moving arm 71 (downward movement operation in FIG. 13), whereby each locking device 74 (hence, Move forward with each engaging hook 76 being accurately positioned with respect to the mold М1,
Each engaging hook 76 enters the engaging recess 64. When the cylinder 75 is operated and the engaging hook 76 is driven in the direction of the arrow in FIG. 21, the engaging hook 76 engages with the engaged portion 64a.

As a result, when the core material assembly 15 is incorporated into the molding die М1, the base frame 51 is engaged with the molding die М1 in advance by the engaging mechanism and then the core material assembly is assembled. Since an assembling force for assembling the three-dimensional body 15 at a predetermined position in the molding die М1 is applied, the assembling operation of the core material assembly 15 is performed with the base frame 51 being engaged with and integrated with the molding die М1 having high rigidity. Therefore, it is possible to prevent the bending of the base frame 51 and to smoothly perform the assembling work. The lock device 74, the engaging hook 76, the engaging concave portion 64, and the engaged portion 64a correspond to the "engaging mechanism" described in the claims of the present application.

Further, two rod members (support rods) 77 are axially slidably inserted through the third horizontal frame 53C via linear bushes 77a (see FIG. 15), and both support members are supported. For example, a pneumatic cylinder (clamp drive cylinder) 78 located in the middle of the rod 77
Is attached. The tip end portion of the piston rod 78p of the clamp drive cylinder 78 and the base end portion of each of the support rods 77 are connected by a connecting member 79 having an L-shaped cross section and arranged above the third horizontal frame 53C in parallel therewith. There is. On the other hand, at the tip of each support rod 77,
A frame member (support frame) 82 having a U-shaped cross section is fixed via a bracket (frame bracket) 81. The support frame 82 extends obliquely below the vertical frame 52A in parallel therewith, and the first clamp device CL1 is fixed to the tip of the support frame 82 via a bracket (clamp bracket) 83. .

Therefore, by operating the clamp drive cylinder 78 from the state shown in FIG. 15 so that the piston rod 78p of the clamp drive cylinder 78 is shortened, the connecting member 79 moves in the direction of approaching the horizontal frame 53C, Along with this, the support frame 82 is connected via each support rod 77 (hence, the first clamp device CL1 connected thereto).
It's designed to move. In contrast, each second
Since the clamp device CL2 is fixed to the tip of the vertical frame 52B via the bracket 57, it does not move up and down with respect to the base frame 51. That is, by driving the clamp driving cylinder 78, the first
Only the clamp device CL1 can be moved forward (moved downward in FIG. 15) and set to a position projecting from the second clamp device CL2.

On the other hand, for example, a pneumatic cylinder device (pressing cylinder) 86 is attached to the vertical frame 52B at a position separated by a predetermined distance in the longitudinal direction. The pressing cylinder 86 is used for the molding work 1 as described later.
When 0 is taken out from the forming die М1, the work 10 is pressed from the front side of the forming die М1 with a force smaller than the push-up force of the ejector mechanism to prevent the work 10 from falling off due to the ejecting operation. Piston rod 86
At the tip of p, a pressing bush 87 whose surface portion is formed of an elastic body such as rubber is attached so as not to damage the work 10 during pressing. Also,
On the center steel plate 54, when the entire base frame 51 is advanced to insert and fix the core material assembly 15 in the molding die М1, the base frame 51 side (that is, the handling device 50 side) and the molding die М1 are attached. In between, a shock absorber 88 having a spring 89 is attached in order to prevent the excessive impact force from being inadvertently applied.

As shown in FIG. 22, an ejector device 120 having an ejector plate 121 for driving each ejector pin 61 after the mold is opened is provided on the back side of the molding die М1 to which the core assembly 15 is insert-fixed. Has been. The ejector plate 121 is moved back and forth by a piston rod 122 of an ejector cylinder (not shown). The ejector plate 121 is integrally provided with a plurality of projecting pins 123.
Is slidably fitted in a guide hole 65 provided in the molding die М1, and each protruding pin 123 smoothly slides in the guide hole 65, so that the ejector plate 1
21 can smoothly move back and forth.

The ejector plate 121 is integrally provided with a plurality of ejector pins 61 that project the molding work 10 when the molding work 10 is taken out from the molding die М1, and each ejector pin 61 is attached to the molding die М1. The ejector hole 62 formed is slidably inserted. When the ejector plate 121 is moved forward, the ejector pins 61 are moved forward accordingly, and the forming work 10 in the forming die М1 is pushed up from the forming surface via the insert 20. . Since the ejector device 120 has the same structure as that well known in the related art and has the same function, further description will be omitted.

As shown in detail in FIG. 23, each nest 20
A pin hole 21b is formed on the bottom surface of the main body portion 21 for receiving the tip end portion of the ejector pin 61, and the ejector pin 61 is ejected when ejecting the insert 20 fitted in the insert recess J1 of the molding die М1. At least one of the tip ends is fitted into the pin hole 21b, and the ejector pin 61 is engaged with the insert body 21. Further, a taper hole 21c is formed on the side surface of the main body portion 21 of the insert 20, and the taper hole 21c is provided with a tip taper portion of the lock pin 67 slidably inserted into the insertion hole 68 of the molding die М1. The insert 20 is adapted to be fitted therein, so that the insert 20 is locked in the insert recess J1 of the molding die М1.

In the present embodiment, as described above, since the ejecting device 120 for ejecting the forming work 10 through the insert 20 after the mold is opened is provided on the back side of the forming mold М1, the inside of the forming mold М1. The ejecting force of the ejecting device 120 does not directly act on the forming work 10 when the forming work 10 is taken out from the work, and it is possible to effectively prevent the core material 16 or the forming work 10 from being bent or deformed by the ejecting operation. it can.

A pressing cylinder 86 that presses the molding work 10 in opposition to the ejecting operation of the molding work 10 (that is, ejecting the nest 20) (that is, exerts a pressing force on the nest 20 via the molding work 10). Is provided on the base frame 51, and the pressing force by the pressing cylinder 86 is set to be smaller than the ejection force of the ejecting device 120. Therefore, the forming work 10 in the forming die М1 is
When the second clamp device CL2 is gripped by the insert 20 via the insert 20, the work piece 1
The insert 20 can be pushed out by the ejecting device 120 while pressing the insert 20 through 0. As a result, before the second clamp device CL2 grips the insert 20, the insert 20 moves the insert 20 (that is,
It is possible to reliably prevent the forming work 10 from accidentally falling off from the forming mold М1. The pressing cylinder 86 corresponds to the "pressing mechanism" described in the claims of the present application. Further, in the present embodiment, for example, the ejecting force of the ejecting device 120 is about 2 to 3 tons, while the pressing force of the pressing cylinder 86 is set to about 3 to 4 kilograms (kg).

The first clamp device CL1 and the second clamp device CL2 have different support structures for the base frame 51, and the first clamp device CL1 can move forward and backward with respect to the base frame 51 as described above. As opposed to
The second clamp device CL2 is different in that it is fixed to the base frame 51, but both CL1 and CL2 have basically the same configuration as the clamp mechanism. For example, the second clamp device CL2 will be described as an example. As shown in FIGS. 17 to 19, the clamp device CL2 includes a pair of clampers 91 extending in a direction perpendicular to the base frame 51. A cylinder (clamper cylinder) 92 for opening and closing the clamper 91 is provided, and the upper surface of the clamper cylinder 92 is fixed to the bracket 57.

Each clamper 91 has a cylinder (holding cylinder) 9 for driving a holding rod 94 extending in the same direction.
3 are connected via a bracket 95. And
With the clamper cylinder 92 being driven and the claw portions 91a of the left and right clampers 91 being engaged with the engaging recesses 21a provided on the side surfaces of the main body portion 21 of the insert 20, respectively, the pressing rod 93 is lowered by the pressing cylinder 93. Then, by pressing the shoulder portion of the insert body 21 with its tip, the inserter 20 can be held by the clamper 91 and the pressing rod 94.

25 to 30 in order to assemble the nest 20 at a predetermined portion of the core material 16 and to remove the nest 20 from the molding work (roof rack) 10 in the relatively vicinity of the molding molds М1 and М2. Thus, the nesting station 100 including the work table 101 is provided. The work table 101 corresponds to the "work base" described in the claims of the present application. The operation of the handling device 50 described above is controlled by a controller provided in a control panel (not shown).
By driving the moving arm 71, the base frame 51 including the clamp devices CL1 and CL2 is reciprocated between the front of the molding die М1 and the upper part of the work table 101 at a predetermined timing, and The base frame 51 is moved back and forth at a predetermined timing. Further, each driving mechanism such as a cylinder for driving each element of the handling device 50, and further, the molding die М.
Each of the drive mechanisms 1 and 2 and each drive mechanism such as a cylinder that drives the ejector device 120 is also connected to the controller (not shown) so that signals can be exchanged between them, and their operations are controlled by command signals from the controller. It is like this.

The work table 101 has a nest 20.
Recessed nest receiving portion 10 for receiving the bottom portion of the body portion 21 of the
Two are provided. 25 to 30, a cross section of the work table 101 is shown, and only the nest 20 combined with the front mounting bracket 17 is shown, but in reality, it is perpendicular to the paper surface of FIGS. 25 to 30. Direction,
The nest receiving portions 102 corresponding to the number of the nests 20 required to form one roof rack 10 (three in the present embodiment) are arranged in a line. Further, in the present embodiment, since the forming molds М1 and М2 are of the two-cavity type, the work table 101 is provided with two rows of the nest receiving portions 102 separated by a predetermined distance.

As shown in FIG. 25, the insert 20 is attached to the receiving surface of each insert receiving portion 102 by a mounting bracket 17 (1
In order to attach / detach the nut 29 to be fixed to (8, 19), a driver hole 103 in which a nut holder 109a of the electric driver 109 is slidably and rotatably axially (up and down) is opened. Also, the work table 101
In order to accurately position the base frame 51 of the handling device 50 with respect to the work table 101, four rows of positioning holes 104 into which the distal end portions of the above-described positioning pins 73 are fitted are mutually formed on the front surface (upper surface) of the. It is formed with a predetermined distance.

Next, the operation of the insert-molded article manufacturing apparatus configured as described above will be described focusing mainly on the operation of the handling apparatus 50. In the following description, as the insert 20 to be assembled at a predetermined portion of the core 16, the insert 20 mainly combined with the mounting bracket 17 on the front side of the core 16 will be described as an example. The same applies to the case of the insert 20 combined with the metal fitting 18 or the rear-side mounting metal fitting 19.

As shown in the flow chart of FIG. 24, first, in step S1, a nesting assembling step of assembling each nesting 20 into a predetermined portion of the core 16 is performed. This nesting assembly process is performed by the handling device 50.
The operation is performed on the work table 101 of the nesting station 100 separately from the operation (in parallel with the operation). That is, for each of the nests 20 placed on each nest receiving portion 102 of the work table 101, each fitting 17
The core member 16 is set while aligning the positions 19 to 19. As a result, the mounting bolts 31 fixed to the bottoms of the mounting brackets 17 to 19 are inserted through the bolt insertion holes 23h formed in the groove receiving surface 23f of the insert 20 into the recesses 25 (see FIGS. 6 to 8). Project.

Then, the electric screwdriver 109 housed in the driver hole 103 is driven, and the nut 29 held by the nut holder 109a is screwed onto the mounting bolt 31 and tightened, whereby each of the mounting brackets 17- 19
And the nest 20 are fixed to each other (see FIG. 25). In other words, each nest 20 on the work table 101
Are assembled to respective predetermined parts of. As a result, the nesting assembly process (step S1) is completed, and the molding die М
A core member assembly 15 to be insert-fixed is formed in the inside 1.

On the other hand, as shown in FIG. 26, the handling device 50 is located above (in front of) the work table 101 as an initial state in the manufacturing cycle. The clamp devices CL1 and CL2 are in the raised position (retracted position). The first clamp device CL1 is located above the nest receiving portion 102 of the work table 101 in an empty state in which nothing is gripped, and the second clamp device CL2.
Is located above a portion separated from the nest receiving portion 101 by a predetermined amount (the amount equal to the distance between the clamp devices CL1 and CL2) while holding the molded work 10 (roof rack). The forming work 10 gripped by the second clamp device CL2 in this initial state is formed by the cycle two cycles before.

From the above initial state, the moving arm 71 is driven to lower the base frame 51 by a predetermined amount, thereby lowering the first and second clamp devices CL1 and CL2 by a predetermined amount (advancing to the work table 101 side). Let). As a result, the tips of the positioning pins 73 fixed to the base frame 51 are positioned at the positioning holes 10 of the work table 101.
4 and the base frame 51 is accurately positioned with respect to the work table 101 (thus, each first clamp device CL1 is with respect to the insert 20 on each insert receiving portion 102).

Then, as shown in FIG. 27, the clamper cylinder 92 of each first clamp device CL1 is driven to clamp the corresponding insert 20. That is, as the first clamping step (step # 1), the core material 16 on the work table 101 is gripped by the first clamping device CL1 via the nest 20. At this time, with respect to each core member 16, what is gripped by the first clamp device CL1 is the insert 20 combined with the front side and rear side mounting brackets 17 and 19, and is combined with the center mounting bracket 18. The nest 20 is free.

Next, in step # 2, the moving arm 71 is driven to raise the base frame 51 (work table 10).
1) to move the positioning pins 73
Of the base frame 51 is removed from the corresponding positioning hole 104, and the base frame 51 is moved by a predetermined amount (both clamp devices CL).
26 and 27 by the amount equal to the interval of 1, CL2).
Move to the left of. As a result, the molded work 1
The respective second clamp devices CL2 holding 0 are located above the nest receiving portion 102 of the work table 101 (see FIG. 28).

Then, in step # 3, the base frame 5
By lowering 1 again (advancing toward the work table 101 side), the forming work 10 gripped by the second clamp device CL2 is set on the nest receiving portion 102 of the work table 101. At this time also, the base frame 51
The tip end portions of the positioning pins 73 fixed to the work tables 101 are fitted into the positioning holes 104 of the work table 101, respectively, and the base frame 51 is attached to the work table 101 (thus, each second clamp device CL2 causes each nest receiving portion 102). Correctly). In this state, the clamper cylinder 92 of the second clamp device CL2 is operated to release the clamping action, so that the molded work 10 is placed on the nest receiving portion 102 via each nest 20 (see FIG. 29). As a result, the second clamp device CL2 is
It becomes empty without any grip.

In this embodiment, as described above, only two rows of the nest receiving portions 102 are provided, but instead of this, the first and second clamp devices CL1, CL are used.
A set of two columns separated by a distance equal to the interval of 2,
Two sets of this may be provided. In this case, the step of raising and moving the base frame in step # 2 is unnecessary, and the first clamping step in step # 1 and the work placing step in step # 3 can be performed at the same time.

After that, the base frame 51 is raised again (retracted from the work table 101 side), and the molded work 1
0 is left in the nest receiving section 102. For each molded work 10 left in the nest receiving portion 102, in step S2, the electric screwdriver 109 (see FIG. 25) is driven, and the nut 29 tightened to the mounting bolt 31 is driven by the nut holder 109a. By screwing off, the fittings 17 to 19 and the insert 20 are released from each other. That is, the insert 20 is removed from the molded work 10 placed on the work table 101.

Then, in step S3, the molded work 10 from which the insert 20 has been removed is carried out to the work storage location. The processes of steps S2 and S3 are performed in parallel with the processes of step # 4 and subsequent steps of the handling device 50, and when the work unloading process of step S3 is completed, the work table 101 of the nesting station 100 displays one cycle of work processes. Ends and returns to the initial state (start).

On the other hand, in the handling device 50, after the molded work 10 is placed on the work table 101 and the base frame 51 is raised in step # 3, the moving arm 71 is driven in step # 4 to drive the base. The frame 51 is moved from above the work table 101 to the front side of the molding die М1 in which the respective nests 20 are incorporated and is rotated by approximately 90 degrees to face the molding die М1 (first moving step). The molding dies М1 and М2 are in the mold open state separated from each other by the first moving step (more preferably, in the initial state of the manufacturing cycle).

By the first moving step described above, as shown in FIG. 31, the first clamp device CL1 that holds the core member 16 through the insert 20 and the empty second clamp device CL2 that holds nothing are It is located on the front side of the molding die М1 in which each nest 20 is incorporated. At this time, the drive amount of the moving arm 71 is controlled so that the empty second clamp device CL2 is located in front of the forming work 10 in the previous cycle left in the forming die М1.

Next, in step # 5, the moving arm 71 is driven to advance the base frame 51 toward the molding die М1 side by a predetermined amount, and the first and second clamp devices CL1 and CL2 are moved by a predetermined amount. Advance to the side. As a result, the tips of the positioning pins 73 fixed to the base frame 51 are fitted into the positioning holes 63 on the surface of the molding die М1, and the base frame 51 is attached to the molding die М1 (accordingly,
The respective second clamp devices CL2 are accurately positioned with respect to the respective nests 20 of the forming work 10 (first positioning step).

Then, as shown in FIGS. 32 and 33, the ejector device 120 provided in the molding die М1 is operated to push up the respective nests 20 by the ejector pins 61, and the clamper cylinders 92 of the respective second clamp devices CL2. To clamp the corresponding insert 20 of the molded work 10. That is, as the second clamping step (step # 6), the molding work 10 of the previous cycle left in the molding die М1 is gripped by the second clamping device CL2 via the insert 20. Also at this time, it is the insert 20 combined with the front side and rear side mounting fittings 17 and 19 that is gripped by the second clamp device CL2 with respect to each molded work 10, and is combined with the center mounting fitting 18. The nest 20 is free.

At this time, as described above, the vertical frame 52 of the base frame 51 supporting the second clamp device CL2.
B, the nest 2 facing the protruding operation of the nest 20
A pressing cylinder 86 exerting a pressing force on 0 is attached, and the pressing force by the pressing cylinder 86 is set to be smaller than the ejecting force of the ejector pin 61 by the ejecting device 120. Then, the above step # 6
In the second clamping step of, the forming work 10 in the forming die М1 is inserted into the second clamping device CL via the nest 20.
When gripping with 2, the forming work 10 is directly pressed by the pressing cylinder 86 via the piston rod 86p and the pressing bush 87, thereby exerting a pressing force on the insert 20 (that is, the forming work). Work 1
While pushing the insert 20 through 0), the insert 20 is ejected by the ejector pin 61. Therefore, before the insert 20 is gripped by the second clamp device CL2, the insert 20 is reliably prevented from being accidentally detached from the mold М1 by the ejecting operation. Incidentally, in the present embodiment, the pressing cylinder 86 is directly connected to the forming work 10.
Although the pressing force is applied to the insert 20 via the molding work 10, the pressing force of the pressing cylinder may directly act on the insert 20 instead.

Next, in step # 7, as shown in FIG. 33, the movable arm 71 is driven to push up the base frame 51 while the ejector pins 61 push up the respective nests 20 by the action of the ejector device 120. By retracting from the М1 side, the respective nests 20 are respectively withdrawn from the recess J1 of the forming die М1, and the forming work 10 in the previous cycle is taken out from the forming die М1 (workpiece taking-out step).

Further, in step # 8, the base frame 5
1 is moved by a predetermined amount (the amount equal to the distance between the two clamp devices CL1, CL2) in the direction of the white arrow in FIG. 33 (that is, upward). As a result, each first clamp device C holding the core material assembly 15 via the nest 20 is provided.
L1 will be located in front of the recess J1 into which the insert 20 of the mold М1 is to be incorporated. The ejector pins 61 are retracted by the time the base frame 51 moves. Then, by moving the base frame 51 back to the molding die М1 side again, as shown in FIG. 34, the positioning pins 7 fixed to the base frame 51 are formed.
The tip end portions of 3 are fitted into the positioning holes 63 on the surface of the molding die М1, respectively, and the base frame 51 is with respect to the molding die М1 (thus, each first clamp device CL1 is with respect to each recess J1 of the molding die М1). , Is accurately positioned (second positioning step).

In this positioning state, the clamp drive cylinder 78 (see FIG. 15) is driven to move the first clamp device CL1 forward to the molding die М1 side while keeping the base frame 51 and the second clamp device CL2 stationary. By doing so, as shown in FIG. 35, each first clamp device CL is
The insert 20 gripped by 1 is fitted into the recess J1 of the forming die М1, and the core material 16 is incorporated into the forming die М1 via the insert 20 (step # 9: core insert step). As described above, since the base frame 51 remains stationary (that is, the second clamp device CL2 remains stationary), only the first clamp device CL1 can be moved forward / backward by the clamp drive cylinder 78, so that the nest 20 is provided. Is held by the first clamp device CL1,
The assembling work for fitting the insert 20 into the recess J1 recessed from the surface of the molding die М1 can be performed without any trouble.

At this time, as described above, the base frame 5
On the lower surface side of each second horizontal frame 53B of No. 1, when the core material assembly 15 is assembled in the molding die М1, the base frame 5
1 is attached to the molding die М1, a locking device 74 having an engagement hook 76 and a cylinder 75 for driving the engagement hook 76 is attached, while the engagement hook 76 is provided at an appropriate position of the molding die М1. An engaging recess 64 having an engaged portion 64a capable of engaging with is provided. Then, in the core material inserting step of step # 9, the core material assembly 15
When assembling into the molding die М1, the base frame 51 is moved forward to the molding die М1 side by the forward movement of the moving arm 71 prior to this assembling work, whereby, as shown in FIG. Each locking device 74 (and hence each engagement hook 76) descends while maintaining the accurate positioning of the base frame 51 with respect to the molding die М1, and each engagement hook 76 enters the engagement recess 64. In this state, the cylinder 75 is operated and the engaging hook 76 is driven in the direction of the arrow in FIG.
Engages with the engaged portion 64a.

That is, the insert 20 gripped by the first clamp device CL1 is fitted into a predetermined position (the insert recess J1) in the molding die М1 to form the core assembly 15 into the molding die М1.
When assembled in the mold, the base frame 51 is previously engaged with the molding die М1 by the engaging mechanism, and then the fitting force for fitting the nest 20 into the nest recess J1 in the molding die М1. Since the base frame 51 is engaged with and integrated with the molding die М1 having high rigidity, the fitting operation of the insert 20 can be performed, which causes bending of the base frame 51. Therefore, the fitting work can be smoothly performed. In particular, in this embodiment, since the insert-molded product is the vehicle roof rack 10 that is long and heavy, more remarkable effects can be obtained.

As described above, the core material assembly 15 is molded into the molding die М.
The first clamp device CL1 is fixed by insert fixing in 1 and by activating the clamper cylinder 92 of the first clamp device CL1 to release the clamp action.
It becomes empty without any grip. Then step #
At 10, the moving arm 71 is driven to move the base frame 51.
Is retracted from the mold М1 (see Fig. 36). And
The base frame 51 is moved from the front side of the molding die М1 to above the work table 101 (second moving step). As a result of this second moving step, as shown in FIG.
The second clamp device CL2 that grips the molded work 10 in the previous cycle and the empty first clamp device CL1 that does not hold anything are positioned above the work table 101 via. That is, the handling device 50 returns (returns) to the initial state (start) of the manufacturing cycle.

When the second moving step of the step # 10 is completed, the molding die М2 is closed to the molding die М1 in step K1 to perform the die clamping (die clamping step).
Then, in step K2, the molten resin is injected and filled with the core material assembly 15 being insert-fixed in the molding cavity МC (injection molding step). After this injection molding process is completed, the molding die М2 is replaced with the molding die М1 in step K3.
After that, the mold is opened apart from, and the manufacturing cycle is returned to the initial state (start).

As described above, according to the present embodiment, the core member assembly 15 is incorporated into the forming die М1 and the forming work 10 is taken out from the forming die М1 through the insert 20. Since the force is not directly applied to the core material 16 or the molding work 10, it is possible to effectively suppress the bending and deformation of the core material 16 in these steps. Further, since the supporting rigidity of the core material 16 in the molding die М1 can be enhanced by using the nest 20, the bending and deformation of the core material 16 due to the injection and filling pressure of the resin can be effectively suppressed. In this case, by adopting the handling device 50, it is possible to accurately and automatically perform an operation such as insert fixing of the core material assembly 15 in the molding die М1 or removal of the molding work 10 from the molding die М1. Therefore, the productivity can be improved.

Particularly, the above-mentioned first and second clamp devices CL1 and CL2 have a common support base (base frame 5).
Since it is supported by 1), it becomes possible to share a moving mechanism and an advancing / retreating mechanism for operating each clamp device, and the structure and operation of the device can be simplified.
In this case, both of the clamp devices CL1, CL2
Are supported by a base frame 51 at a predetermined distance, and the base frame 51 common to both is provided above the working table 101 or in front of the molding die М1 by a control means at a pitch equal to the predetermined distance. Since the clamp devices CL1 and CL2 are controlled to move, the operations to be performed by the clamp devices CL1 and CL2 on the work table 101 or the molding die М1 can be sequentially and smoothly performed without interfering with each other.

Although the above description has been made by taking the case of applying to the insert molding of the roof rack 10 for a vehicle as an example, the present invention is not limited to such a case and other It can also be effectively applied when various products are manufactured by the insert molding method. In particular, it is effective for a relatively long product and a product having a large weight (not only the product weight but also the weight including the insert core material and the insert). As described above, it is needless to say that the present invention is not limited to the above-described embodiments, and various improvements and modifications or design changes can be made without departing from the scope of the invention.

[0075]

According to the manufacturing apparatus of the first invention of the present application, the first clamp mechanism holds the core material through the insert, and fits the insert into a predetermined position in the molding die. The core material can be incorporated in the molding die, and the second clamping mechanism holds the molding work in the molding die through the insert, and the insert is removed from a predetermined position of the mold to remove the insert from the mold. The molded work can be taken out and the taken-out molded work can be set on the front surface of the work base. That is, since the incorporation of the core material into the molding die and the removal of the molding work from the molding die are all performed through the nest, no force is directly applied to the core material or the molding work. It is possible to effectively suppress the occurrence of bending and deformation of the core material in the. Further, since the supporting rigidity of the core material in the molding die can be increased by using the nest, the bending and deformation of the core material due to the injection and filling pressure of the resin can be effectively suppressed. In this case, since the advancing / retreating operation and the moving operation of the first clamping mechanism and the second clamping mechanism are controlled by the advancing / retreating mechanism and the moving mechanism, and the clamping operation is directly controlled by the control means, it is possible to move into the molding die. It is possible to accurately and automatically perform an operation such as inserting the core material or taking out the work from the molding die, thereby improving the productivity.

According to the second invention of the present application, basically, the same effect as that of the first invention can be obtained. In particular, since the above-mentioned forming die is provided with an eject mechanism for ejecting the forming work through the insert after opening the die, the ejecting force by the eject mechanism directly acts on the forming work when taking out the forming work from the forming die. Therefore, it is possible to effectively prevent the core material or the molded work from being bent or deformed by the ejecting operation. Further, a pressing mechanism for exerting a pressing force on the insert is provided on the support base supporting the second clamp mechanism so as to face the protruding operation of the insert, and the pressing force by the pressing mechanism is smaller than the ejecting force of the eject mechanism. Since it is set, the forming work in the forming die is inserted into the second
When gripping with the clamp mechanism, the insert mechanism can push out the nest while pressing the nest with the action of the pressing mechanism, and the nest is carelessly ejected by the eject operation before the nest is gripped with the second clamp mechanism. It is possible to reliably prevent problems such as falling off from the mold.

Further, according to the third invention of the present application, basically, the same effect as that of the first or second invention can be obtained. In particular, a support base that supports the first clamp mechanism is provided with an engagement mechanism that allows the support base to be engaged with the mold, and inserts that are gripped by the first clamp mechanism into the mold. When fitting the core material into a molding die by fitting it at a predetermined location, the support mechanism is engaged with the molding die in advance by the engaging mechanism, and then the nest is placed in the molding die. Since a fitting force for fitting at a predetermined location is applied, the nesting operation can be performed in a state where the support base is engaged with and integrated with a mold having high rigidity, and the support base is bent. It is possible to prevent this from occurring and to perform this fitting work smoothly.

Furthermore, according to the fourth invention of the present application, basically, the same effect as that of any one of the first to third inventions can be obtained. In particular, since the first clamp mechanism and the second clamp mechanism are supported by a common support base, it is possible to share a moving mechanism and an advancing / retreating mechanism for operating the respective clamp mechanisms, and thus the device The structure and operation can be simplified. In this case,
Both clamp mechanisms are supported at a predetermined distance, and the common support base is moved by the control means in front of the work base or in front of the mold at a pitch equal to the predetermined distance. Since the clamp mechanisms are controlled, the operations to be performed by the clamp mechanisms on the work base or the mold can be sequentially and smoothly performed without interfering with each other.

Furthermore, according to the fifth invention of the present application, basically, the same effect as that of any one of the first to fourth inventions can be obtained. Particularly, since the insert-molded product is a vehicle roof rack which is generally relatively long and heavy, more remarkable effects can be obtained.

Further, according to the manufacturing method of the sixth aspect of the present invention, the first clamp mechanism holds the core material through the insert in the first clamp step and molds the insert in the core insert step. It is possible to fit the core material into a molding die by fitting it to a predetermined position in the inside of the molding die. Further, the second clamping mechanism grips the molding work in the molding die through the nest in the second clamping step, In the take-out step, the insert can be removed from a predetermined portion of the forming die to take out the forming work from the forming die, and in the work setting step, the taken-out forming work can be set on the front surface of the work base. That is, since the incorporation of the core material into the molding die and the removal of the molding work from the molding die are all performed through the nest, no force is directly applied to the core material or the molding work. It is possible to effectively suppress the occurrence of bending and deformation of the core material in the. Also,
By using the nest, the support rigidity of the core material in the molding die can be increased, so that the bending and deformation of the core material due to the injection and filling pressure of the resin can be effectively suppressed. In this case, the forward / backward movement and the movement operation of the first clamp mechanism and the second clamp mechanism are performed through the forward / backward movement mechanism and the movement mechanism, and the clamp operation is directly performed.
By the automatic control, it is possible to accurately and automatically perform operations such as inserting the core material into the molding die or taking out the work from the molding die, thereby improving the productivity.

Further, according to the seventh invention of the present application, basically the same effect as that of the sixth invention can be obtained. Particularly, since the molding die is provided with an eject mechanism for ejecting the molded work through the insert after the mold is opened, the ejecting force by the eject mechanism directly acts on the molded work when the molded work is taken out from the molding die. Therefore, it is possible to effectively prevent the core material or the molded work from being bent or deformed by the ejecting operation. Further, when the molded work in the molding die is grasped by the second clamp mechanism via the insert, the insert is opposed to the ejecting force of the eject mechanism and a pressing force smaller than that is applied to the insert. Since the forming work is gripped via the insert, the insert can be ejected by the eject mechanism while exerting a pressing force on the insert, and before the insert is grasped by the second clamp mechanism, the insert is carelessly ejected from the forming die by the ejecting operation. It is possible to reliably prevent problems such as falling off.

Further, according to the eighth invention of the present application, basically, the same effect as that of the sixth or seventh invention can be obtained. In particular, when the insert clamped by the first clamp mechanism is fitted at a predetermined position in the mold to incorporate the core into the mold, the support base supporting the first clamp mechanism is molded. A state in which the supporting base is engaged with and integrated with a highly rigid molding die because a fitting force for fitting the nest at a predetermined position in the molding die is applied in a state of being engaged with the die. It is possible to perform the fitting operation of the insert, and to prevent the bending of the support base, so that the fitting operation can be smoothly performed.

Furthermore, according to the ninth invention of the present application, basically, the same effect as that of the sixth to eighth inventions can be obtained. Particularly, since the insert-molded product is a vehicle roof rack which is generally relatively long and heavy, more remarkable effects can be obtained.

[Brief description of drawings]

FIG. 1 is an overall perspective view of an automobile equipped with a roof rack according to an embodiment of the present invention.

FIG. 2 is a plan view of the roof rack.

FIG. 3 is a side view illustrating the roof rack.

FIG. 4 is a perspective view of a core member to which each fitting is integrally fixed.

5 is a vertical cross-sectional explanatory view of the roof rack taken along line VV in FIG.

FIG. 6 is a perspective view of a nest used for insert molding of the roof rack.

FIG. 7 is a longitudinal cross-sectional explanatory view showing a portion in which a nest of a molding die used for the insert molding is set.

FIG. 8 is a vertical cross-sectional explanatory view of the molding die taken along the line VIII-VIII in FIG. 7.

FIG. 9 is a perspective view showing the roof rack and accessories at the time of assembly.

FIG. 10 is a longitudinal cross-sectional explanatory view showing a fixed state of the front side mounting leg portion of the roof rack.

11 is a vertical cross-sectional explanatory view of the mounting leg portion taken along line XI-XI in FIG.

FIG. 12 is a vertical cross-sectional explanatory view of the mounting bracket in a state of being set in the molding die, for illustrating a modified example of the mounting bracket.

FIG. 13 is a side view schematically showing the overall structure of a handling device used for insert molding of the roof rack.

14 is an explanatory view schematically showing the overall configuration of the handling device, and is a view taken in the direction of the arrow Y14-Y14 in FIG.

FIG. 15 is an explanatory view schematically showing a clamp device provided in the above-mentioned handling device, which is Y15 in FIG.
It is an arrow line view from the -Y15 direction.

FIG. 16 is a front explanatory view of the first clamp device.

FIG. 17 is a front explanatory view of a second clamp device.

FIG. 18 is a side view of the second clamp device.

FIG. 19 is an explanatory diagram of the second clamp device shown in FIG.
6 is a view from the direction of Y19-Y19 in FIG.

FIG. 20 is a partial vertical cross-sectional explanatory view showing a positioning pin provided in the handling device and a positioning hole of a molding die.

FIG. 21 is a partial vertical cross-sectional explanatory view showing a lock device provided in the handling device and an engaging recess of a mold.

FIG. 22 is a side view of a forming die and a forming work showing an ejecting operation of the forming die ejector device.

FIG. 23 is a vertical cross-sectional explanatory view of a nest fitted in the recess of the molding die.

FIG. 24 is a flow chart for explaining a roof rack manufacturing process using the handling device.

FIG. 25 is an explanatory view showing a part of a series of steps in the nesting station, and is a partial cross-sectional explanatory view of the working table and the nesting.

FIG. 26 is an explanatory view showing a part of a series of steps in the nesting station, and is a partial cross-sectional view of the handling device, the work table and the nest.

FIG. 27 is an explanatory view showing a part of a series of steps in the nesting station, and is a partial cross-sectional view of the handling device, the work table and the nest.

FIG. 28 is an explanatory view showing a part of a series of steps in the nesting station, and is a partial cross-sectional explanatory view of the handling device, the work table and the nest.

FIG. 29 is an explanatory diagram showing a part of a series of steps in the nesting station, and is a partial cross-sectional explanatory diagram of the handling device, the work table and the nest.

FIG. 30 is an explanatory view showing a part of a series of steps in the nesting station, and is a partial cross-sectional explanatory view of the operator table and the nesting.

FIG. 31 is an explanatory view showing a part of a series of steps on the front side of the molding die and is a partial cross-sectional explanatory view of the handling device, the working table and the insert.

FIG. 32 is an explanatory diagram showing a part of a series of steps on the front side of the molding die, and is a partial cross-sectional explanatory diagram of the handling device, the working table and the insert.

FIG. 33 is an explanatory view showing a part of a series of steps on the front side of the molding die and is a partial cross-sectional explanatory view of the handling device, the working table and the insert.

FIG. 34 is an explanatory view showing a part of a series of steps on the front side of the molding die, and is a partial cross-sectional explanatory view of the handling device, the working table and the insert.

FIG. 35 is an explanatory diagram showing a part of a series of steps on the front side of the molding die, and is a partial cross-sectional explanatory diagram of the handling device, the working table and the insert.

FIG. 36 is an explanatory view showing a part of a series of steps on the front side of the molding die, and is a partial cross-sectional explanatory view of the handling device, the working table and the insert.

[Explanation of symbols]

2 ... Vehicle roof 3 ... Roof panel 10 ... Roof rack 11 ... Rack body 12,13,14 ... Mounting legs 15 ... Core material assembly 16 ... Core material 17, 18, 19, 47 ... Mounting bracket 20 ... Nesting 51 ... Base frame 61 ... Ejector pin 64 ... Engagement recess 64a ... Engagement part 71 ... Moving arm 74 ... Locking device 76 ... Engaging hook 78 ... Clamp drive cylinder 86 ... Pressing cylinder 87 ... Pressing bush 101 ... Work table 102 ... Nesting part 120 ... Ejecting device CL1 ... First clamp device CL2 ... Second clamp device J1 ... Nesting recess M1, M2 ... Mold MC: Molding cavity

─────────────────────────────────────────────────── ─── Continuation of front page (58) Fields surveyed (Int.Cl. ⁷ , DB name) B29C 45/14 B29C 45/26 B60R 9/04

Claims (9)

(57) [Claims] 1. An insert-molded article in which a core material is previously incorporated in a molding die and a molten resin is filled in a molding cavity so that a predetermined surface region or the whole of the core material is covered with a synthetic resin. A manufacturing apparatus used for manufacturing, including a nesting operation of assembling a nest fitted at a predetermined location in the molding die at a predetermined location of the core material, and a nest removal operation of removing the nest from the core material of the molding work. A work base for performing the work is provided, and a first clamp mechanism capable of gripping a core material via the nest, a second clamp mechanism capable of gripping a molded work via the nest, and a nest incorporating these clamp mechanisms. A moving mechanism that reciprocates between the front of the molding die and the front of the work base, and each of the clamp mechanisms with respect to the molding die and the work base. An advancing / retreating mechanism for advancing / retreating, and a control means for driving / controlling the advancing / retreating mechanism, the moving mechanism, and the clamp mechanism, respectively, wherein the first clamp mechanism is mounted on the work base via a nest. After gripping the core material, the core is incorporated into the molding die by fitting the core into a predetermined position in the molding die, and the second clamp mechanism is formed in the molding die via the core. After gripping the work, the mold is taken out of the mold by removing the insert from a predetermined portion of the mold, and the clamp mechanisms are set so that the taken-out work is set on the front surface of the work base. A device for manufacturing an insert-molded product, characterized in that each is driven and controlled. 2. The molding die is provided with an ejecting mechanism for ejecting a molding work through a nest after opening the die, while a support base supporting the second clamp mechanism is opposed to the ejecting operation of the nest. 2. The apparatus for manufacturing an insert-molded product according to claim 1, wherein a pressing mechanism for exerting a pressing force on the insert is provided, and the pressing force by the pressing mechanism is set to be smaller than the ejecting force of the eject mechanism. . 3. A support base for supporting the first clamp mechanism is provided with an engagement mechanism capable of engaging the support base with a mold, and is gripped by the first clamp mechanism. When the core is fitted into a molding die at a predetermined position to incorporate the core into the molding die, the support mechanism is previously engaged with the molding die by the engagement mechanism, and The insert molding product manufacturing apparatus according to claim 1 or 2, wherein a fitting force for fitting the insert into a predetermined position in the molding die is applied. 4. The first clamp mechanism and the second clamp mechanism are supported on a common support base at a predetermined distance, and the control means sets the common support base in front of the work base or The apparatus for manufacturing an insert-molded product according to any one of claims 1 to 3, wherein the device can be controlled to move at a pitch equal to the predetermined distance in front of the molding die. 5. The insert-molded product includes a rack body extending in the vehicle front-rear direction on the upper side of the vehicle roof, and a mounting portion to the vehicle body roof, and the mounting portion and the outside of the rack body are covered with a synthetic resin. It is a roof rack for vehicles which becomes, The manufacturing apparatus of the insert molded product as described in any one of Claims 1-4. 6. An insert-molded article in which a core material is incorporated in a molding die in advance and a molding cavity is filled with a molten resin so that a predetermined surface region or the whole of the core material is covered with a synthetic resin. A manufacturing method, wherein a nesting step of assembling a nest fitted at a predetermined location in the molding die at a predetermined location of the core material, and a core material arranged on a work base by the first clamp mechanism The first clamp step of gripping through the nest, the work setting step of unclamping the molded work gripped by the second clamp mechanism and setting it on the front surface of the work base, and the work setting step on the front surface of the work base. And removing the insert from the forming work, and moving the first and second clamp mechanisms from the front of the work base to the front of the forming die in which the insert is incorporated. A first moving step, a first positioning step of positioning the second clamp mechanism with respect to the forming die, and a second cycle of the second clamp mechanism for holding a forming work of the previous cycle in the forming die through a nest. A second clamping step; a workpiece removing step of removing the forming work of the previous cycle from the forming die by removing the insert gripped by the second clamping mechanism from a predetermined position in the forming die; 2 a second positioning step of moving the second clamp mechanism by a predetermined amount to position the first clamp mechanism with respect to the mold, and fitting the nest held by the first clamp mechanism into a predetermined position in the mold. The core material inserting step of incorporating the core material into the mold by combining the core material and the first and second clamp mechanisms to the front of the mold. The second movement process and method for producing insert molded article comprising the moving forward of Luo said work base. 7. When gripping a forming work in the forming die by the second clamp mechanism, the ejecting mechanism provided in the forming die ejects the forming work through the nest, and the ejecting force is applied to the forming work. 7. The method for manufacturing an insert-molded article according to claim 6, wherein a molding work is gripped through the insert while applying a pressing force facing the insert and smaller than the pressing force. 8. When fitting the insert gripped by the first clamp mechanism into a predetermined position in a mold, the first clamp mechanism is used.
7. The fitting force for fitting the nest at a predetermined position in the molding die is applied with the support base supporting the clamp mechanism engaged with the molding die. 7. The method for manufacturing the insert-molded article according to 7. 9. The insert-molded product comprises a rack body extending in the vehicle body front-rear direction on the upper side of the vehicle roof, and a mounting portion to the vehicle body roof, and the mounting portion and the outside of the rack body are covered with a synthetic resin. 9. The method for manufacturing an insert-molded article according to claim 6, which is a roof rack for a vehicle.