Method of molding a first resin member on a second resin member

A method of molding a resin member formed by solidifying molten resin M on a resin member on which molding is to be performed, includes first to third steps. The first step includes setting, on the member on which molding is to be performed, a first mold having a first cavity for molding a portion corresponding to a base portion of the resin member. The second step includes setting, on the first mold, a second mold having a second cavity for molding a portion corresponding to a main body portion of the resin member. The second cavity is formed so as to communicate with the first cavity. The third step includes pouring molten M resin into each of the cavities of both of the molds that have been set, and solidifying the molten resin M thus poured such that it is bonded to the member on which molding is to be performed.

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention relate to a resin member molding method and a molding apparatus. More specifically, the invention relates to a method of molding a resin member, formed by solidifying molten resin, on a resin member on which molding is to be performed, and to an apparatus used for carrying out the method.

2. Background of Technology

As a method of mounting a resin design plate to a target member such as a console box of an automobile, there is known a method in which the mounting is effected via, for example, a resin clip. In this connection, Japanese Laid-Open Patent Publication No. 2002-355848 discloses a method in which a plate of a desired configuration is previously molded of resin, and a clip is molded (directly molded) at a desired position on the molded plate. When molding is thus performed, the clip and the plate are formed into an integral structure, so that it is possible to achieve an improvement in terms of workability when mounting the plate to the target member.

However, in the method of Japanese Laid-Open Patent Publication No. 2002-355848 described above, the edge of a plate130, for example, is curved, and, when a clip is to be molded in the vicinity of a base end of the curved edge, a mold118of a molding machine interferes with the curved edge (InFIG. 9, the phantom line indicates the interfering state), so that this method has a problem in that the clip can only be molded at the position on the mold118indicated by the solid line inFIG. 9. This problem might be coped with by replacing the mold118with another, different mold; in that case, however, it would be necessary to prepare a plurality of molds according to the degree to which the plate130is curved, resulting in increase in production cost and low operational efficiency.

Therefore, there is a need in the art for a resin molding method and a molding apparatus that enable to mold a resin member on a different resin member without need of mold replacement.

SUMMARY OF EMBODIMENTS OF THE INVENTIONS

In general, a method of molding a resin member formed by solidifying molten resin on a resin member on which molding is to be performed is taught. Embodiments of the method include a first step of setting, on the member on which molding is to be performed, a first mold having a first cavity for molding a portion corresponding to a base portion of the resin member. Embodiments of the method further include a second step of setting, on the first mold, after the first step, a second mold having a second cavity for molding a portion corresponding to a main body portion of the resin member. The second cavity is formed so as to communicate with the first cavity. Embodiments of the method further include a third step of pouring, after the second step, molten resin into each of the cavities of both of the molds that have been set, and solidifying the poured molten resin such that it is bonded to the member on which molding is to be performed.

According to certain embodiments this method, when molding the resin member on the member on which molding is to be performed, the main body portion of the resin member is formed by the second mold, and the base portion of the resin member is formed by the first mold, so that it is possible to perform the molding, with the resin member increased in height by the height of the base portion. Thus, even in the case where, as described in connection with the known technique, the edge of the member on which molding is to be performed is curved, and where the resin member is to be molded in the vicinity of the base end of the curved edge, the second mold may not interfere with the curved edge. Thus, there is no need to replace the second mold, and it is possible to mold the resin member in the vicinity of the base end of the curved edge. Further, as described above, it is possible to perform molding on the member on which molding is to be performed, with the resin member increased in height, so that even in a case where, for example, the target member requires an increase in the height of the resin member, the requirement can be met without having to replace the second mold.

An apparatus for molding a resin member, formed by solidifying molten resin, on a resin member on which molding is to be performed, includes a base on which the member on which molding is to be performed can be set; a first mold capable of being set on the member on which molding is to be performed that has been set on the base; and a second mold capable of being set on the first mold. The, the first mold has a first cavity for molding a portion corresponding to a base portion of the resin member. The second mold has a second cavity for forming a portion corresponding to a main body portion of the resin member. The second cavity is formed so as to communicate with the first cavity. Molten resin may be poured into the cavities of both of the molds, with the first mold set on the member on which molding is to be performed and which has been set on the base, and with the second mold set on the first mold thus set. The poured molten resin is solidified so as to be bonded to the member on which molding is to be performed.

Also according to this apparatus, it is possible to attain the same advantages as the method described above.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTIONS

An example will be hereinafter described with reference toFIGS. 1 through 8. In the example described bellow, a resin plate30serves as a resin member on which molding is to be performed. Similarly, in the example described below, a clip36used when the resin plate30is mounted to a target member, to which the resin plate30is mounted, serves as a resin member. First, referring toFIG. 1, the construction of a direct molding machine1, which is an example of a molding apparatus will be described.

Numeral10indicates a frame constituting the base of the direct molding machine1. Numeral12indicates a base placed on the top surface of the frame10. The base12is used to set the resin plate30in order to mold the clip36on the resin plate30described below. Numeral14indicates a pole extending upward from the top surface of the frame10. The pole14is used to vertically slide a mounting frame16described below.

Numeral16indicates the mounting frame. Assembled to the mounting frame16is a mold18for molding the clip36on the resin plate30. Further, assembled to the mounting frame16is a handle20used for injecting molten resin M into a cavity18bof the mold18.

Numeral18indicates the mold. Formed in the mold18are a nozzle18aallowing injection of the molten resin M, and the cavity18bto be filled with the molten resin M injected from the nozzle18a. The cavity18bis configured to mold a main body portion36aof the clip36. The cavity18bis formed such that, when the mold18is set on a jig40described below, it communicates with a through-hole42bof one of molds42described below.

The mold18has a pin18cthat can be inserted into a hole42cformed in each of the molds42of the jig40described below.

The direct molding machine1is constituted by the frame10, the base12, the pole14, the mounting frame16, the mold18, and the handle20.

Next, the construction of the jig40will be described with reference toFIG. 2. The jig40is composed of two molds42, and a connection bar46assembling the two molds42together. The molds42serve as a first mold. Each mold42has a recess42ain the upper surface thereof. This enables each mold42to receive the forward end of the mold18.

In a part of the bottom surface of each recess42a, there is formed a through-hole42bvertically extending therethrough. The through-hole42bis the cavity for molding the base portion (proximal portion) of the clip36. The through-hole42bserves as a first cavity. Further, a support bar44is formed on each mold42for assembling with the connection bar46. The support bar44has an elongated hole44aextending in the longitudinal direction thereof. Further, each of the molds42has holes42cinto which the pin18cof the mold18described above can be fitted.

The connection bar46also has an elongated hole46aextending in the longitudinal direction thereof. The connection bar46has at one end thereof an L-shaped bent portion46b.

A bolt48is inserted into the elongated hole46aof the connection bar46and into the elongated holes44aof the support bars44formed on the molds42, and, in the inserted state, the bolt48is threadedly engaged with a nut50(not shown inFIG. 2) to assemble the molds42to the connection bar46, thus forming the jig40. At this time, as is apparent also fromFIG. 2, the two molds42are assembled to the connection bar46such that they are respectively situated on opposite sides with respect to the connection bar46while being oriented in opposite directions.

When the threaded engagement between the bolt48and the nut50is loosened, it is possible to slide the two molds42in the longitudinal direction of the connection bar46and in the longitudinal direction of the support bar44. And, after the molds42have been slid to desired positions, the threaded engagement of the bolt48and the nut50is tightened, whereby it is possible to effect positioning of the two molds42at desired positions with respect to the connection bar46.

The jig40is constituted by the two molds42and the connection bar46.

Next, a method of molding three clips36on the resin plate30by using the direct molding machine1and the jig40described above will be described with reference toFIGS. 3 through 8. First, the resin plate30is previously molded by another molding machine (not shown). As in the case of the resin design plate described in connection with the known art, the resin plate30is formed so as to have a curved edge.

The resin plate30is set on the base12of the direct molding machine1(SeeFIG. 3). Next, the bent portion46bof the connection bar46is hooked on the edge of the resin plate30, and, in this state, the jig40is set on the resin plate30. At this time, the jig40is set on the resin plate30so that the two molds42are positioned at positions where the clips36are to be molded. As in the case described in connection with the known art, in this embodiment, the jig40is set on the resin plate30such that the clips36are molded in the vicinity of the base end of the curved edge (SeeFIG. 4).

Next, the mounting frame16is lowered, so that a leading end18dof the mold18enters the recess42aof one of the molds42. At this time, the leading end18dof the mold18enters the recess42aof the mold42such that the pin18cis fitted into the hole42cof the mold42. As a result, the mold18is positioned relative to the mold42, so that the through-hole42bof the mold42and the cavity18bof the mold18communicate with each other (SeeFIG. 5). The mounting frame16may be lowered such that the resin plate30receives a pressure if needed or desired.

Next, the handle20is operated for injecting the molten resin M from the nozzle18aof the mold18into the cavity18band further into the through-hole42b. After that, the molten resin M that has been injected is solidified so as to be bonded to the resin plate30(SeeFIG. 6). Next, the mounting frame16is raised and the leading end18dof the mold18is retreated from the recess42aof the mold42to detach the jig40from the resin plate30(SeeFIG. 7). In this way, it is possible to mold the clip36on the resin plate30.

Subsequently, the resin plate30is changed in its orientation, and is set on the base12of the direct molding machine1again. And, the above operations described with reference toFIGS. 3 through 7are repeated to mold two additional clips36on the resin plate30. In this way, it is possible to mold three clips36on the resin plate30(SeeFIG. 8). InFIG. 8, the left lower clip36as seen in this figure is the one molded by the steps described with reference toFIGS. 3 through 7.

According to the molding method of this example, when molding the clips36on the resin plate30, the main body portions36aof the clips36are molded by the mold18, and the base portions36bof the clips36are molded by the jig40, so that it is possible to mold the clips36on the resin plate30while increasing their height by the height of the base portions36b. Thus, even when the edge of the resin plate30is curved, and the clips36are to be molded in the vicinity of the base end of the curved edge, the mold18of the direct molding machine1may not interfere with the curved edge. That is, it is possible to set the mold18so as to be horizontally in conformity with the mold indicated by the phantom line inFIG. 9illustrating the known art. Thus, it is possible to mold the clips36in the vicinity of the base end of the curved edge without need of replacing the mold18. Further, as described above, it is possible to mold the clips36on the resin plate30while increasing them in height, so that even if the target member requires, for example, increase in the height of the clips36, the requirement can be met without need of replacing the mold18.

According to the molding apparatus of this example, it is possible to attain the same advantages as those of the above-described molding method.