Abstract:
A mold includes a body, a first movable member and a second movable member. The body defines a first cavity. The first movable member defines a second cavity. The first movable member reciprocates along a predetermined movement axis with respect to the mold. The second movable member is movable along the movement axis with respect to the first movable member in the body for selectively connecting and disconnecting the second cavity and the first cavity according to the movement of the second movable member. A first material is supplied to one of the first cavity and the second cavity with the first and second cavities disconnected from each other. Then a second material is supplied to the other one of the first and second cavities with the first and second cavities connected to each other.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention is related to a mold for supplying two or more kinds of materials into a cavity to form an integrally molded article, and more particularly to a mold for injection molding an integrally molded article using two kinds of high polymer materials.  
           [0002]    Conventionally, when an integrally molded article is molded by two materials, for example, one fixed mold is used and a different movable mold is necessary for each material. Therefore, the mold clamping and the mold opening are necessary every time a different movable mold is used, and molding efficiency is decreased.  
         SUMMARY OF THE INVENTION  
         [0003]    The objective of the present invention is to provide a mold for molding an integrally molded article, which mold efficiently uses two or more than materials.  
           [0004]    To achieve the above object, the present invention provides a mold for molding an integrally molded article using at least two kinds of materials. The mold includes a body, a first movable member and a second movable member. The body defines a first cavity. The first movable member defines a second cavity. The first movable member reciprocates along a predetermined movement axis with respect to the mold. The second movable member is movable along the movement axis with respect to the first movable member in the body for selectively connecting and disconnecting the second cavity and the first cavity according to the movement of the second movable member. A first material is supplied to one of the first cavity and the second cavity with the first and second cavities disconnected from each other. Then a second material is supplied to the other one of the first and second cavities with the first and second cavities connected to each other.  
           [0005]    The present invention provides another a mold for molding an integrally molded article using at least two kinds of materials. The mold includes a body, a first movable member and a second movable member. The body defines a first cavity. The first movable member defines a second cavity. The first movable member moves with respect to the mold. The second movable member slides along the first movable member, while contacting the first movable member in the body. The second movable member selectively connects and disconnects the second cavity and the first cavity in accordance with the movement of the second movable member. A first material is supplied to one of the first cavity and the second cavity with the first and second cavities disconnected from each other. Then a second material is supplied to the other one of the first and second cavities with the first and second cavities connected to each other.  
           [0006]    The present invention provides another a mold for molding an integrally molded article using at least two kinds of materials. The mold includes a body, a first movable member and a second movable member. The body defines a first cavity. The first movable member defines a second cavity. The second movable member is arranged on the first movable member in the body and movable with the first movable member and with respect to the first movable member for selectively connecting and disconnecting the second cavity and the first cavity. A first material is supplied to one of the first cavity and the second cavity with the first and second cavities disconnected from each other. Then a second material is supplied to the other one of the first and second cavities with the first and second cavities connected to each other.  
           [0007]    The present invention provides another a mold for molding an integrally molded article using at least two kinds of materials. The mold includes a body, a first movable member and a second movable member. The body defines a first cavity. The first movable member defines a second cavity. The first movable member is movable with respect to the mold. The second movable member is movable in the body so as to be in contact with and apart from the first movable member for selectively connecting and disconnecting the second cavity and the first cavity in accordance with the movement of the second movable member. A first material is supplied to one of the first cavity and the second cavity with the first and second cavities disconnected from each other. Then a second material is supplied to the other one of the first and second cavities with the first and second cavities connected to each other.  
           [0008]    The present invention also provides a manufacturing method for molding an integrally molded article using at least two kinds of materials. The method includes defining a first cavity by approaching a movable mold to a fixed mold; defining a second cavity by moving a first movable member with respect to the movable mold along a predetermined movement axis to a closed position; disconnecting a first cavity and a second cavity by moving the second movable member with respect to the first movable member along the movement axis to a disconnecting position while a first and a second cavities are formed; supplying a first material to one of the first and the second cavities while the second cavity is disconnected from the first cavity; connecting the first and the second cavities by moving the second movable member from the disconnecting position to an open position; supplying a second material to the other one of the first and the second cavities while the second cavity is connected to the first cavity; and releasing the first and the second cavities by separating the movable mold from the fixed mold and moving the first movable member and the second movable member from the closed position to the open position.  
           [0009]    Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:  
         [0011]    [0011]FIG. 1 is a partial cross-sectional view showing mold clamping of a mold according to a first embodiment of the present invention before a material is supplied to a cavity;  
         [0012]    [0012]FIG. 2 is a partial cross-sectional view showing that a material is supplied to a first cavity of the mold shown in FIG. 1;  
         [0013]    [0013]FIG. 3 is a partial cross-sectional view showing that a material is supplied to a second cavity of the mold shown in FIG. 2;  
         [0014]    [0014]FIG. 4 is a partial cross-sectional view showing mold opening of the mold shown in FIG. 3;  
         [0015]    [0015]FIG. 5 is a partial cross-sectional view showing mold clamping of a mold according to a second embodiment before a material is supplied to a cavity;  
         [0016]    [0016]FIG. 6 is a partial cross-sectional view showing a material is supplied to a first cavity of the mold shown in FIG. 5;  
         [0017]    [0017]FIG. 7 is a partial cross-sectional view showing a material is supplied to a second cavity of the mold shown in FIG. 6; and  
         [0018]    [0018]FIG. 8 is a partial cross-sectional view showing mold opening of the mold shown in FIG. 7. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]    Hereinafter, an injection mold  1  according to a first embodiment of the present invention will be explained with reference to FIGS.  1 - 4 .  
         [0020]    A body  2  of the mold  1  shown in FIG. 1 comprises a fixed mold  3  that is arranged on an upper side in FIG. 1 and a movable mold  4  that is arranged on a lower side in FIG. 1. The movable mold  4  reciprocates along a vertical direction Z. FIGS.  1 - 3  show a mold clamping condition U (closed position) where the movable mold  4  approaches the fixed mold  3 . FIG. 4 shows a mold opening condition D (open position) where the movable mold  4  is apart from the fixed mold  3 .  
         [0021]    A first movable member  5  is supported on an upper surface of the movable mold  4  that faces the fixed mold  3  so as to reciprocate along a horizontal movement axis X. A second movable member  6  having a extended portion  6   a  and a hydraulic cylinder  7  that serves as an actuator are placed on the first movable member  5 . A piston rod  7   a  is connected to the second movable member  6 . The second movable member  6  has a slide surface S that contacts the first movable member  5 . The second movable member  6  moves along the horizontal movement axis X with respect to the first movable member  5  between a forward position F 2  shown in FIG. 1 and a rear position R 2  shown in FIGS.  2 - 4  in accordance with the movement of the piston rod  7   a  along the horizontal movement axis X.  
         [0022]    A pin  8  that serves as a movement mechanism is fixed to the fixed mold  3 . A hole  9  that serves as a movement mechanism is formed in the movable mold  4  and the first movable member  5 . The pin  8  and the hole  9  are slanted with respect to the vertical direction Z and the movement axis of the movable mold  4 . The pin  8  is inserted to and removed from the hole  9  in accordance with the movement of the movable mold  4  with respect to the fixed mold  3 . More in detail, as shown in FIGS.  1 - 3 , when the pin  8  is inserted to the hole  9  in accordance with the upward movement of the movable mold  4 , the mold is in the mold clamping condition U and the first movable member  5  is moved to the forward position F 1  (closed position) with the second movable member  6  and the hydraulic cylinder  7 . As shown in FIG. 4, when the pin  8  is removed from the hole  9  in accordance with the downward movement of the movable mold  4 , the mold is in the mold opening condition D, the first movable member  5  is moved to the rear position R 1  (open position) with the second movable member  6  and the hydraulic cylinder  7 .  
         [0023]    In a first molding condition P shown in FIG. 1, each of the first and second movable members  5 ,  6  is positioned in the forward position F 1 , F 2  respectively. In this condition, a first cavity  10  is formed between the fixed mold  3  and the movable mold  4  and a second cavity  11  is formed between the movable mold  4  and the first movable member  5 . In the first molding condition P, the extended portion  6   a  of the second movable member  6  is extended between an end portion  10   a  of the first cavity  10  and an end portion  11   a  of the second cavity  11  to disconnect the end portion  11   a  of the second cavity  11  from the end portion  10   a  of the first cavity  10 . On the other hand, when the second movable member  6  is moved from the forward position F 2  (closed position) to the rear position R 2  (open position) in the first molding condition P, the mold is in a second molding condition Q shown in FIG. 2. In the second molding condition Q, the extended portion  6   a  of the second movable member  6  withdraws from between the end portion  10   a  of the first cavity  10  and the end portion  11   a  of the second cavity  11 . As a result, the first cavity  10  is released so that the end portion  11   a  of the second cavity  11  is communicated with the end portion  10   a  of the first cavity  10 .  
         [0024]    Next, a manufacturing method for manufacturing an integrally molded article  14  will be explained.  
         [0025]    In the first molding condition P shown in FIG. 1, a melted first material  12  is supplied to only the first cavity  10  via a first passage (not shown) (refer to FIG. 2). Next, in the second molding condition Q shown in FIG. 2, a melted second material  13  is supplied to the second cavity  11  via a second passage (not shown) (refer to FIG. 3). As a result, as shown in FIG. 3, the second material  13  in the second cavity  11  is integrally connected with the first material  12  in the first cavity  10 . Next, while the movable mold  4  moves downwardly so as to be apart from the fixed mold  3 , the first movable member  5  is moved to the rear position R 1  by the operation of the pin  8  and the hole  9 . As shown in FIG. 4, in the mold opening condition D, the first and second movable members  5 ,  6  are separated from the integrally molded article  14  including the solidified first material  12  and the second material  13  and the molded article  14  can be taken out easily from the mold.  
         [0026]    This embodiment has following advantages.  
         [0027]    The molded article  14  including the first and the second materials  12 ,  13  can be formed efficiently by carrying out the mold clamping and the mold opening once with one mold  1 . Moreover, the mold  1  of a compact and a simple structure is provided by arranging the first and the second movable members  5 ,  6  closer to each other.  
         [0028]    Next, an injection mold  101  according to a second embodiment of the present invention will be explained with reference to FIGS.  5 - 8 .  
         [0029]    A body  102  of a mold  101  shown in FIGS.  5 - 8  comprises a fixed mold  103  that is arranged on an upper side in the drawings and a movable mold  104  that is arranged on a lower side in the drawings. The movable mold  104  reciprocates along a vertical movement axis Z. FIGS.  5 - 7  show a mold clamping condition U (closed position) where the movable mold  104  approaches the fixed mold  103 . FIG. 8 shows a mold opening condition D (open position) where the movable mold  104  is apart from the fixed mold  103 .  
         [0030]    A first movable member  105  is supported by the movable mold  104  between the movable mold  104  and the fixed mold  103  so as to reciprocate along the vertical movement axis Z. A second movable member  106  is supported by the fixed mold  103  between the movable mold  104  and the fixed mold  103  so as to reciprocate along the vertical movement axis Z.  
         [0031]    A hydraulic cylinder  107  that serves as an actuator is arranged on the movable mold  104 . A conduction member  108  is arranged on a piston rod  107   a  of the hydraulic cylinder  107 . The conduction member  108  has a slanted conduction surface  109  that contacts the first movable member  105 . When the piston rod  107   a  of the hydraulic cylinder  107  moves along the horizontal direction X, the first movable member  105  moves along the vertical movement axis Z via the conduction member  108  between a lower position A 1  shown in FIG. 5 and an upper position B 1  shown in FIGS.  6 - 8 . The second movable member  106  is hung from the fixed mold  103  by a rod  110  and urged toward the first movable member  105  by a compression coil spring  111  wound around the rod  110 . The second movable member  106  is arranged at the lower position A 2  by an elastic force of the compression coil spring  111  in the mold clamping condition U shown in FIG. 5 and the mold opening condition D (open position) shown in FIG. 8. The second movable member  106  is arranged at the upper position B 2  against the elastic force of the compression coil spring  111  in the mold clamping condition U shown in FIGS. 6, 7. The second movable member  106  moves between the lower position A 2  and the upper position B 2 .  
         [0032]    In a first molding condition P shown in FIG. 5, a first cavity  112  is formed between the fixed mold  103  and the movable mold  104 . The first movable member  105  is arranged at the lower position A 1  and the second movable member  106  is arranged at the lower position A 2 . A part of a facing surface  105   a  of the first movable member  105  and a part of a facing surface  106   a  of the second movable member  106  are pressed with each other by the elastic force by the compression coil spring  111 . A second cavity  113  is formed between portions of the facing surfaces  105   a,    106   a  that do not contact with each other. A closing surface  106   b  of the second movable member  106  disconnects an end portion  113   a  of the second cavity  113  from an end portion  112   a  of the first cavity  112  at the lower position A 2 . When the first and the second movable members  105 ,  106  are moved to the upper positions B 1 , B 2  respectively from the first molding condition P shown in FIG. 5, the mold is in a second molding condition Q shown in FIG. 6. In the second molding condition Q, the closing surface  106   b  of the second movable member  106  is apart from end portion  112   a  of the first cavity  112 . As a result, the end portion  113   a  of the second cavity  113  is communicated to the end portion  112   a  of the first cavity  112 .  
         [0033]    Next, a manufacturing method for manufacturing an integrally molded article  116  will be explained.  
         [0034]    In the first molding condition P shown in FIG. 5, a melted first material  114  is supplied to only the first cavity  112  via a first passage (not shown). Next, in the second molding condition Q shown in FIG. 6, a melted second material  115  is supplied to the second cavity  113  via a second passage (not shown) (refer to FIG. 7). As shown in FIG. 7, the second material  115  in the second cavity  113  is integrally connected with the first material  114  in the first cavity  112 . Next, while the movable mold  104  moves downwardly so as to be apart from the fixed mold  103 , the second movable member  106  is moved to the lower position A 2  by the urging force of the coil spring  111  (refer to FIG. 8). As shown in FIG. 8, in the mold opening condition D, the integrally molded article  116  including the solidified first material  114  and the second material  115  is separated from the second movable member  106 . As a result, the integrally molded article  116  can be taken out from the mold. In the second embodiment, the same advantages as the first embodiment shown in FIGS.  1 - 4  are obtained.  
         [0035]    The embodiments may be modified as follows.  
         [0036]    The second cavity  13 ,  113  shown in FIGS.  1 - 8  may be formed by only the first movable member  5 ,  105  respectively. In other words, the second cavity  13 ,  113  is necessarily formed by the first movable member  5 ,  105 . The first cavity  10 ,  112  may be formed between the second movable member  6 ,  106  and the body  2  respectively. In other words, the first cavity  10 ,  112  is necessarily formed by the body  2 .  
         [0037]    The second movable member  6 ,  106  shown in FIGS.  1 - 8  is not necessarily arranged directly on the first movable member  5 ,  105  respectively. Another member may be arranged between the second movable member  6 ,  106  and the corresponding first movable member  5 ,  105 .  
         [0038]    The second movable member  6 ,  106  shown in FIGS.  1 - 8  is necessarily movable with respect to the first movable member  5 ,  105  respectively, however, the movement direction of the second movable member  6 ,  106  is not limited.  
         [0039]    It should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Particularly, it should be understood that the invention may be embodied in the following forms.  
         [0040]    Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalence of the appended claims.