JPH0431484B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of manufacturing an article, which includes a step of assembling parts by caulking and a step of casting a synthetic resin.

[Prior Art] A magnetic clutch for an automobile air conditioner, which is an example of an article manufactured by the method of the present invention, was previously manufactured by the potting method as shown in the side sectional view of FIG. It was assembled into a structure. 3 is a metal housing of the magnetic clutch, 1 is an excitation coil, 7 is an insulating tape applied to the outer periphery of the coil 1, and 9 is a periphery of the coil 1 supported in a floating state within the annular housing 3. This is a potting composition such as epoxy resin that is filled into the voids of the resin by a casting method. Reference numeral 5 designates a disc-shaped support member for mounting the magnetic clutch, which is welded to the housing 3.

Later, a simple processing method using caulking was adopted, and magnetic clutches with an assembly structure as shown in the side cross-sectional view of FIG. 7 began to be manufactured. A coil winding spool 2 made of hard synthetic resin is fixed to the inner circumferential wall surface of the annular housing 3 by a caulking portion 3a of the housing 3. 8 is a powder coating layer made of synthetic resin for covering the exposed portion of the coil 1.

However, according to the assembly structure shown in FIG. 7, the spool 2 gradually wears out at the caulking part 3a due to vibrations during operation of the magnetic clutch, and the pressure force is lost.
In order to secure the fixation more reliably, a synthetic resin injection molding method, which is much more productive than the potting method described above, is used in combination with the caulking method described above, as shown in Figure 2 as a combination of the above two methods. and third
Assembly structures such as those depicted in the figures as a side sectional view and a plan view, respectively, have come to be adopted. 4 is a synthetic resin molded into the housing 3 by injection molding; 6a is a lead wire of the coil 1;
is the wiring terminal attached to housing 3,
The lead wire 6 and the outgoing wire 6a are soldered at point a.
connected with.

[Problems to be Solved by the Invention] There remains room for further improvement in the method of manufacturing the newest magnetic clutch having the structure shown in FIGS. 2 and 3 above.

This is because, although the spool 2 is fixed to the housing 3 with a sufficiently high degree of reliability,
Because it requires two completely different steps: a caulking process and a synthetic resin injection molding process.
This will lead to an increase in production costs in terms of both equipment and workability.

The present invention is not limited to the above-mentioned magnetic clutch, but it is an object of the present invention to provide a method for more efficiently manufacturing an article that involves a caulking process and a synthetic resin casting process in the manufacturing process.

[Means for Solving the Problems] In order to achieve the above object, the method for manufacturing an article according to the present invention provides a synthetic resin article having a divided structure and a caulking punch attached to the inside of at least one of the divided molds. placing a metal housing or frame member of an article within a forming mold; and placing a main body member, which forms the main body of the article and is at least partially made of a rigid material, into the mold; At the same time as clamping the mold,
A configuration is adopted that includes a step of caulking the rigid portion of the main body member to the metal housing, and a step of casting a synthetic resin into the remaining gap in the mold.

[Function] A method for manufacturing an article using an injection molding machine having the above-mentioned configuration is to first fix the housing or frame member of the article and the main body member of the article inside a synthetic resin mold by caulking them together. Store it while maintaining the desired positional relationship. At the same time, other parts of the article are placed in the mold.

After that, when the mold is closed and the mold is clamped using the mold clamping press attached to the synthetic resin molding machine, the caulking punch attached to the inside of the mold presses the caulked part and the product is closed. The main body portion is caulked and fixed to the housing or frame member of the article.

Next, a synthetic resin is cast into the remaining void in the mold to form a synthetic resin part of the article, and if necessary, the caulked part is covered with a synthetic resin layer to caulk. Further strengthen the assembly structure.

[Example] The manufacturing method according to the present invention will be specifically described below based on the example shown in the accompanying drawings.

1 to 5 are diagrams showing the case of manufacturing a magnetic clutch for an air conditioner of an automobile as an article.

Magnetic clutch A is shown in the second longitudinal sectional view.
It has the structure depicted in FIG. 3 as a diagram and a plan view. The excitation coil 1 is wound into a spool 2 which is an annular body having an open outer peripheral surface. The spool 2 is made of high hardness engineering plastic or metal.

Reference numeral 3 denotes a clutch case made of metal such as iron or aluminum, and a disc-shaped arm support 5 for attaching the rotating shaft of the clutch is welded to one flat surface of a hollow annular body having a rectangular cross section. The other flat surface is open to form an annular groove, and the coil 1 wound on the spool 2 is fitted into the annular groove of the clutch case 3.

When the coil 1 is accommodated in the annular groove of the clutch case 3, a gap remains between the outer circumferential surface of the coil 1 and the inner circumferential surface of the annular groove and on the upper surface of the spool 2. The remaining void is filled with a thermoplastic synthetic resin having good electrical insulation, heat resistance, mechanical strength, etc., such as polyethylene resin, by injection molding.

In order to firmly fix the spool 2 of the coil 1 in the clutch case 3 while resisting vibrations during operation of the magnetic clutch, it is necessary to attach a groove in the circumferential direction to the open side edge of the inner circumferential wall of the annular clutch case 3. Spot-shaped caulking portions 3a are provided at appropriate intervals, and the spool 2 is pressed against the case 3 at these portions.

9 is a wiring terminal attached to the clutch case 3, and serves to connect the lead wires 6a at both ends of the coil 1 to the power supply lead wire 6. A is a connection point between the coil 1 and the lead wire 6 by soldering.

Figure 1 shows that the clutch case 3 of magnetic clutch A is housed inside a two-part mold of a synthetic resin injection molding machine, and the two processes of injection molding and caulking described above are performed almost simultaneously. FIG. 2 is a longitudinal cross-sectional view of a mold portion of the manufacturing device, showing the situation.

Reference numerals 11 and 12 in the figure are an upper mold and a lower mold of a mold having a two-part structure for injection molding. In this example, the lower mold 1
A casting space is provided in 2, and a clutch case 3 is fitted into this space.

The upper mold 11 includes a spool portion 12 as an introduction path for the molten synthetic resin, a runner portion 13 as a distribution path,
In addition to the provision of a gate 14 as an injection port, a desired number of caulking punches 10 are attached to the contact surface with the lower die 12 at desired locations by screwing or other appropriate methods. 15 is a member for sealing the mold mating surface.

In FIG. 5, which shows the overall configuration of the apparatus used to carry out the method of the present invention as a front view including a partial sectional view, B is a synthetic resin injection molding machine;
21 and 22 are a fixed plate and a movable plate for mold clamping, 23 is a mold clamping ram, 30 and 31 are injection cylinders and screws, 32 is an injection nozzle part, 33 is a rotating shaft for driving the screw 31, and 34 is a synthetic resin It is a raw material hopper.

Next, a method of manufacturing the above magnetic clutch will be explained with reference to FIG. 4, which is a manufacturing process diagram.

First, the mold clamping ram 23 is lowered to separate the lower mold 12 from the upper mold 11 and bring it into an open state.
The clutch case 3 is tightly fitted into the inner cavity of the mold (FIG. 4-A).

Next, insert the coil 1 into the annular groove of the clutch case 3.
Set the spool 2, which is wound with the spool 2, as shown in Figure 4-B.

Thereafter, when the mold clamping ram 23 is raised, the mold mating surface (top surface) of the lower mold 12 is brought closer to the mold mating surface (bottom surface) of the upper mold 11, and the mold is attached to the bottom surface of the upper mold 11. The caulking punch 10 begins to bite into the caulking point 3a at the top of the inner peripheral side wall of the annular clutch case 3, and when the mold clamping is completed, the clutch case 3 is closed as shown in Fig. 4-C. The caulking and fixing of the spool 2 is completed.

When the completion of mold clamping is confirmed by a position sensor or the like, the injection molding machine B automatically injects a predetermined amount of molten plastic 4 into the clutch case 3 as shown in Fig. 4D. Since the remaining casting gap is injected to fill this gap, the uneven portions of the caulked portion 3a are also embedded in the cooled and hardened synthetic resin layer, and the spool 2 and the spool against the clutch case 3 are Excitation coil 1 wound on
The fixed state becomes more solid and reliable. Therefore, the intense vibration acting force accompanying the rapid on-off operation and rotational movement of the magnetic clutch damages the clutch case 3.
Even if the clutch case 3 is
There is no risk of the coil 1 rotating inside the case or falling out of the case, and there is no possibility of a failure in which the coil 1 is disconnected near the connection point to the wiring terminal 9.

The above embodiment describes a method for manufacturing a magnetic clutch, but the feature of the method for manufacturing an article according to the present invention is the step of assembling the component members of the article by a caulking method, and the step of assembling the other component members of the article. Since the manufacturing process using a synthetic resin injection molding machine is carried out simultaneously with the mold tightening operation, this manufacturing method consists of a combination structure of metal parts and synthetic resin parts. It can also be applied to various items.

When a mold for molding synthetic resin has a split structure into three or more parts, a plurality of caulking punches may be attached to each of the two or more split molds, or if necessary, a mold for attaching punches may be attached to the mold. If a method is adopted in which the auxiliary member is detachably assembled, caulking can be performed at a desired location on the article.

Furthermore, in the above embodiments, an injection molding machine is used as the synthetic resin molding machine, but depending on the shape and structure of the article to be manufactured or the type of synthetic resin, a compression molding machine, a transfer molding machine, etc. may be used. The manufacturing method according to the present invention can also be carried out as an example. Furthermore, even when a sheet-shaped thermoplastic synthetic resin is subjected to hot-press molding, the object of the present invention can be achieved by attaching a caulking punch to the press mold.

[Effects of the Invention] In the method for manufacturing an article according to the present invention as described above, a caulking punch is attached to at least one of the molds having two or more divided structures for injection molding of synthetic resin. In the mold clamping process when injection molding the synthetic resin part of the article, a metal housing or frame member as another component of the article is placed in advance in the mold and is integrally molded with the synthetic resin. and a main body member made at least partially of a rigid material can be caulked and fixed at the same time.

Therefore, equipment and work space for manufacturing articles can be saved, and the production process can be greatly shortened.

If necessary, by covering the caulking area with a synthetic resin layer, it is possible to further increase the assembly strength of the caulking area.

[Brief explanation of drawings]

1 to 5 are diagrams illustrating the case where a magnetic clutch for an automobile air conditioner as an article is manufactured by the manufacturing method according to the present invention. Figure 1 is a longitudinal sectional view of the completed magnetic clutch housed in the mold, Figures 2 and 3 are longitudinal sectional views and plan views of the magnetic clutch, and Figure 4 is the manufacturing process. FIG. 5 is a front view showing the overall configuration of the manufacturing apparatus. FIGS. 6 and 7 are longitudinal cross-sectional views of two types of magnetic clutches made by conventional manufacturing methods, respectively. In the diagram, A... Goods (magnetic clutch), B
...Synthetic resin injection molding machine, 1, 2...Main member of article, 3...Metal housing (clutch housing), 3a...Caulking point, 4...Synthetic resin layer, 10...Punch for caulking , 11, 12...
...Two-part mold.

Claims (1)

[Claims] 1 (a) The metal housing or frame member of the article is housed inside a synthetic resin mold that has a split structure and has a caulking punch attached to the inside of at least one of the split molds. (b) placing a main body member, which forms the main body of the article and is at least partially made of a rigid material, into the mold; (c) at the same time as clamping the mold, A method for producing an article using a synthetic resin molding machine, comprising the steps of caulking a rigid portion of the main body member to the metal housing, and (d) casting a synthetic resin into the remaining void in the mold. 2. A method of manufacturing an article using a synthetic resin molding machine according to claim 1, wherein the article is a magnetic clutch for an air conditioner for an automobile.