CN110091472B

CN110091472B - Mold device and resin component

Info

Publication number: CN110091472B
Application number: CN201910090901.7A
Authority: CN
Inventors: 高须良平
Original assignee: Koito Manufacturing Co Ltd
Current assignee: Koito Manufacturing Co Ltd
Priority date: 2018-01-30
Filing date: 2019-01-30
Publication date: 2022-02-11
Anticipated expiration: 2039-01-30
Also published as: JP2019130712A; CN210174081U; JP7007207B2; CN110091472A

Abstract

The invention provides a mold device and a resin component, which can reduce the occurrence of poor molding of the resin component. The mold apparatus is an apparatus for molding a resin member. The resin member is an elongated body having: a 1 st end, a 2 nd end, a 1 st recess proximate the 2 nd end and extending about the axis of the resin component, and a 2 nd recess in the 2 nd end extending axially forward of the 1 st recess. The mold device has a mold forming a molding space. The mold has: a gate for injecting molten resin, connected to the 1 st region of the molding space corresponding to the 1 st end portion; a 1 st projection disposed near a 2 nd region of the molding space corresponding to the 2 nd end; a 2 nd convex part arranged in the 2 nd region; and a 3 rd convex part extending from the tip of the 2 nd convex part toward the 1 st region side. The tip of the 3 rd convex part is located on the 1 st region side of the 1 st convex part.

Description

Mold device and resin component

Technical Field

The present invention relates to a mold device and a resin member, and more particularly to a mold device for manufacturing a resin member used in a vehicle lamp and a resin member manufactured by the mold device.

Background

Conventionally, various components have been used in a lamp such as a headlight of an automobile. Each member is manufactured by various methods according to the shape and material thereof. For example, a lamp for an automobile includes a collimator device for adjusting an optical axis direction which is a reference of a light irradiation direction. The calibration device is provided with a member called an optical axis adjustment screw for adjusting the optical axis. The optical axis adjusting screw is also referred to as a calibration screw.

In some cases, the entire optical axis adjusting screw is formed of metal in order to ensure mechanical strength, but from the viewpoint of weight reduction, a member using a resin material has been studied. On the other hand, since a resin material is inferior in strength to a metal material, the entire member may be increased in size to some extent in order to secure strength. In this case, the effect of weight reduction is reduced due to the increase in size. Therefore, a technique of forming a cavity in a part of the screw for optical axis adjustment has been studied (see patent document 1). In this technique, the desired strength and weight reduction of the component itself are achieved by manufacturing the screw for optical axis adjustment having the hollow.

Patent document 1: japanese patent laid-open publication No. 2013-82430

In recent years, higher functions of lamps mounted on automobiles and the like have been advanced. For example, as an example of advanced lamp functions, an adb (adaptive Driving beam) technique has been proposed in which a light distribution pattern of high beam is dynamically and adaptively controlled based on a state of the surroundings of a vehicle. The ADB technology detects the presence or absence of a preceding vehicle, a reverse vehicle, or a pedestrian in front of the vehicle, and reduces glare given to the vehicle or the pedestrian by dimming or turning off an area corresponding to the vehicle or the pedestrian.

As the vehicle lamp becomes multifunctional as described above, the size and weight of the vehicle lamp have been increased. In order to increase the size and weight of the vehicle lamp, the optical axis adjusting screw needs to be elongated. On the other hand, if the screw for optical axis adjustment is long, it becomes difficult to diffuse the molten resin in the cavity of the mold, and the possibility of occurrence of molding failure increases.

Disclosure of Invention

The present invention has been made in view of the above circumstances, and an object thereof is to provide a technique for reducing the occurrence of molding failure of a resin member.

In order to solve the above problem, one embodiment of the present invention is a mold apparatus. The mold apparatus is used for molding a resin member. The resin member is an elongated body elongated in one direction, and has: 1 st end part; a 2 nd end opposite to the 1 st end; a 1 st recess portion which is disposed near the 2 nd end portion and extends around the axis of the resin member; and a 2 nd recess extending in the 2 nd end portion to a position just before the 1 st recess in the axial direction of the resin member. The mold device has a mold that forms a molding space corresponding to the resin member. The mold has: a gate connected to a 1 st region of the molding space corresponding to the 1 st end portion, for injecting a molten resin into the molding space; a 1 st convex part which is arranged near a 2 nd area of the molding space corresponding to the 2 nd end part and corresponds to the 1 st concave part; a 2 nd convex part which is arranged in the 2 nd area and corresponds to the 2 nd concave part; and a 3 rd convex part extending from the tip of the 2 nd convex part toward the 1 st region side, and the tip of the 3 rd convex part is positioned on the 1 st region side of the 1 st convex part. According to this aspect, the occurrence of molding defects of the resin member can be reduced.

In the above aspect, the mold may include: a 1 st die corresponding to a 1 st end portion and an intermediate portion between the 1 st end portion and the 2 nd end portion; and a 2 nd mold corresponding to the 2 nd end portion, the 1 st mold having a gate and a 1 st convex portion, the 2 nd mold having a 2 nd convex portion and a 3 rd convex portion. In any of the above-described aspects, the resin member may have a hollow portion extending from the 1 st end portion over at least a part of an intermediate portion between the 1 st end portion and the 2 nd end portion, and the mold may have a gas injection port connected to the 1 st region for injecting gas into the molding space. In any of the above-described aspects, the resin member may be an optical axis adjusting screw for adjusting a light emission direction of the vehicle lamp.

Another embodiment of the present invention is a resin member. The resin member is an elongated body elongated in one direction, and has: 1 st end part; a 2 nd end opposite to the 1 st end; a 1 st recess portion which is disposed near the 2 nd end portion and extends around the axis of the resin member; a 2 nd recess extending in the 2 nd end portion in the axial direction of the resin member to a position just before the 1 st recess; and a 3 rd recess extending from the tip of the 2 nd recess toward the 1 st end side, the tip of the 3 rd recess being located on the 1 st end side of the 1 st recess.

In the above aspect, a sealing member may be further provided, and the sealing member may be fitted into the 1 st recess. In any of the above-described aspects, the resin member may be an optical axis adjusting screw for adjusting a light emission direction of the vehicle lamp.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the present invention, the occurrence of molding defects of the resin member can be reduced.

Drawings

Fig. 1 is a vertical cross-sectional view showing a schematic structure of a vehicle headlamp apparatus including a resin member according to an embodiment.

Fig. 2 (a) is a side view showing a schematic structure of a resin member according to the embodiment. Fig. 2 (B) is a view showing a schematic structure of the resin member when viewed from the rear side of the lamp.

Fig. 3 is a vertical cross-sectional view showing a schematic structure of a resin member.

Fig. 4 is a cross-sectional view showing a schematic structure of a mold device according to an embodiment.

Fig. 5 is a perspective view showing a schematic structure of a part of the die apparatus.

Fig. 6 (a) and 6 (B) are views schematically showing a process for producing a resin member.

Fig. 7 (a) and 7 (B) are views schematically showing a process for producing a resin member.

Fig. 8 (a) is a diagram schematically showing the flow of the molten resin in the mold device according to the reference example. Fig. 8 (B) is a diagram schematically showing the flow of the molten resin in the mold device according to the embodiment.

Fig. 9 (a) is a plan view showing a schematic structure of a 3 rd projection according to modification 1. Fig. 9 (B) is a side view showing a schematic structure of the 3 rd projection according to modification 1.

Fig. 10 (a) is a plan view showing a schematic structure of a 3 rd projection according to modification 2. Fig. 10 (B) is a side view showing a schematic structure of a 3 rd projection according to modification 2.

Description of the reference numerals

100 optical axis adjusting screws, 102 1 st end portion, 104 nd end portion, 106 middle portion, 116 st recess portion, 122 nd recess portion, 124 rd recess portion, 126 hollow portion, 130 molten resin, 200 th mold device, 202 th mold, 204 molding space, 204a 1 st region, 204b 2 nd region, 206 st mold, 208 nd mold, 2 nd mold, 220 gate, 222 gas injection port, 230 st projection portion, 248 nd projection portion, 250 nd projection portion.

Detailed Description

The present invention will be described below based on preferred embodiments with reference to the drawings. The embodiments are not intended to limit the invention but to exemplify the invention, and all the features and combinations thereof described in the embodiments are not necessarily limited to the essential contents of the invention. The same or equivalent components, members and processes shown in the respective drawings are denoted by the same reference numerals, and overlapping descriptions are omitted as appropriate. The scale and shape of each part shown in the drawings are set for convenience of explanation, and are not to be construed as limiting unless otherwise specified. Even if the same member is used, the scale and the like may slightly differ between the drawings. In addition, when the terms "1 st", "2 nd", and the like are used in the present specification or claims, unless otherwise specified, they are not intended to indicate any order or importance, but are intended to distinguish one structure from another.

(headlight device for vehicle)

First, a vehicle headlamp apparatus using the resin member according to the present embodiment will be described. Fig. 1 is a vertical cross-sectional view showing a schematic structure of a vehicle headlamp apparatus including a resin member according to an embodiment. The vehicle headlamp apparatus 1 includes a pair of headlamp units disposed on the left and right sides in front of the vehicle. Since a pair of headlamp units have substantially the same structure except for the bilaterally symmetrical structure, fig. 1 shows the structure of one headlamp unit.

The vehicle headlamp apparatus 1 includes: a lamp body 2 having an opening on a vehicle front side; and a light-transmitting cover 4 that covers the opening of the lamp body 2. A lamp unit 8 as a vehicle lamp is housed in a lamp chamber 6 formed by the lamp body 2 and the translucent cover 4. The lamp unit 8 includes a light source mounting portion 10, a light source 12, a reflector 14, a projection lens 16, and a bracket portion 18.

The light source mounting portion 10 is made of a heat conductive material such as aluminum. The light source mounting portion 10 has a light source mounting stage 20 that faces in a direction intersecting the optical axis O of the lamp unit 8. The light source 12 is mounted on the light source mounting stage 20. The light source 12 is, for example, a semiconductor light emitting element such as an LED (light emitting diode), an LD (laser diode), or an organic or inorganic EL (electroluminescence). The light source mounting unit 10 includes a plurality of heat radiation fins 22 on the back surface side of the light source mounting stage 20. Heat emitted from the light source 12 is dissipated via the heat dissipating fins 22. The light source mounting portion 10 has a light-shielding cover portion 24 extending obliquely downward from the end portion of the light source mounting stage 20 on the front side of the lamp.

The reflector 14 is fixed to the light source mounting portion 10 so as to cover the upper side of the light source 12. The mirror 14 has a reflecting surface 26 formed by a portion of a surface of revolution. The reflecting surface 26 has a 1 st focal point and a 2 nd focal point located on the front side of the lamp as compared with the 1 st focal point. The reflector 14 is positioned relative to the light source 12 such that the light-emitting surface of the light source 12 substantially coincides with the 1 st focal point of the reflecting surface 26. The reflector 14 is positioned relative to the light source mounting unit 10 such that the ridge line formed by the light source mounting stage 20 and the shade cover portion 24 is positioned in the vicinity of the 2 nd focal point of the reflection surface 26.

The projection lens 16 is coupled to an end portion of the light source mounting unit 10 on the front side of the lamp. The projection lens 16 is formed of a plano-convex aspherical lens, and projects a light source image formed on a rear focal plane as an inverted image onto a virtual vertical screen in front of the lamp. The projection lens 16 is disposed on the optical axis O of the lamp unit 8 at a position where the rear focal point substantially coincides with the 2 nd focal point of the reflecting surface 26.

The light emitted from the light source 12 is reflected by the reflection surface 26, passes through the vicinity of the ridge line formed by the light source mounting stage 20 and the light-shielding cover portion 24, and enters the projection lens 16. The light of the light source 12 incident on the projection lens 16 is emitted as substantially parallel light toward the front of the lamp. In addition, a part of the light source light is selectively cut with the ridge line as a boundary line. Thereby, a light distribution pattern having a cutoff line corresponding to the shape of the ridge line is projected to the front of the vehicle.

The bracket portion 18 includes: a 1 st portion 28 extending above the light source mounting portion 10; and a 2 nd portion 30 extending to a lower side of the light source mounting portion 10. The 1 st part 28 has a screw hole 32 at a predetermined position. The lamp body 2 has a screw support portion 34 at a position overlapping the screw hole 32 in the front-rear direction of the lamp. The screw support portion 34 is a tubular shape extending in the front-rear direction of the lamp, and the inside and the outside of the lamp body 2 communicate with each other by the screw support portion 34.

The screw 100 for optical axis adjustment is inserted through the screw support portion 34 from the outside of the lamp body 2. The optical axis adjusting screw 100 is rotatably supported by the screw supporting portion 34. Further, the optical axis adjusting screw 100 is screwed into the screw hole 32 of the bracket portion 18. The structure of the optical axis adjusting screw 100 will be described in detail later.

The 2 nd part 30 has a pivot member 36 at a prescribed position. The pivot member 36 projects from the 2 nd portion 30 toward the rear of the lamp, and a ball 38 for a ball joint is provided at the tip of the pivot member 36. The lamp body 2 has joint support portions 40 at positions overlapping the pivot members 36 in the front-rear direction of the lamp. The joint support 40 projects from the lamp body 2 toward the front of the lamp, and a ball receiving portion 42 is provided at the tip of the joint support 40. The ball receiving portion 42 has a spherical space along the shape of the ball portion 38. The ball portion 38 is rotatably coupled to the ball receiving portion 42, whereby the pivot member 36 is coupled to the joint support portion 40.

The bracket portion 18, the optical axis adjusting screw 100, and the joint support portion 40 constitute an optical axis adjusting mechanism of the lamp unit 8. The lamp unit 8 can be tilted about the ball portion 38 of the pivot member 36 as a fulcrum by rotating the optical axis adjusting screw 100. This allows the optical axis O of the lamp unit 8 to be adjusted in the vertical direction. Although not shown, the lamp unit 8 is coupled to 2 optical axis adjustment screws 100 arranged in the horizontal direction. Therefore, the optical axis O of the lamp unit 8 can be adjusted in the horizontal direction.

The structure of the lamp unit 8 described above is merely an example, and the lamp unit 8 may have another structure known in the art. The structures of the pivot member 36 and the joint support portion 40 are not particularly limited.

(screw for adjusting optical axis)

Next, the structure of the screw 100 for adjusting the optical axis will be described. The optical axis adjusting screw 100 is a member for adjusting the light emitting direction, in other words, the optical axis O of the lamp unit 8 as the vehicle lamp, and is an example of a resin member according to the present embodiment. Fig. 2 (a) is a side view showing a schematic structure of a resin member according to the embodiment. Fig. 2 (B) is a schematic view of the structure of the resin member as viewed from the rear side of the lamp. Fig. 3 is a vertical cross-sectional view showing a schematic structure of a resin member. Fig. 2 (B) and 3 also illustrate a part of the lamp body 2. Fig. 3 corresponds to a cross-sectional view taken along line a-a in fig. 2 (B).

The screw 100 for adjusting the optical axis as a resin member is formed by injection molding of resin using the mold device according to the embodiment. Further, since the gear portion is made of metal, strictly speaking, the screw 100 for optical axis adjustment is formed by insert molding. The optical axis adjusting screw 100 is an elongated body elongated in one direction (specifically, the front-rear direction of the lamp), and has a 1 st end portion 102, a 2 nd end portion 104 opposite to the 1 st end portion 102, and an intermediate portion 106 between the 1 st end portion 102 and the 2 nd end portion 104. Hereinafter, the extending direction of the optical axis adjusting screw 100, in other words, the direction in which the 1 st end 102 and the 2 nd end 104 are aligned is referred to as the axial direction X of the optical axis adjusting screw 100.

The intermediate portion 106 is provided with a thread forming portion 108, a coupling portion 110, and a support shaft portion 112 in this order from the 1 st end portion 102 side. A screw groove is formed on the surface of the thread forming portion 108. The thread forming portion 108 is screwed into the screw hole 32 of the bracket portion 18. The coupling portion 110 is a portion that couples the thread forming portion 108 and the support shaft portion 112. A pair of elastic engaging portions 114 project from the outer peripheral surface of the coupling portion 110 near the 1 st end portion 102.

The support shaft 112 has a 1 st recess 116 extending around the axis (circumferential direction) of the optical axis adjusting screw 100. The 1 st recess 116 is disposed at a position closer to the 2 nd end 104 of the optical axis adjusting screw 100, that is, closer to the 2 nd end 104 than the 1 st end 102. In the present embodiment, the 1 st recess 116 is disposed in the vicinity of the 2 nd end 104. A sealing member 118 such as an O-ring is fitted into the 1 st recess 116. The support shaft 112 is housed in the screw support portion 34 of the lamp body 2. In this state, the seal member 118 is in close contact with the inner wall of the screw support portion 34. This prevents moisture from entering the lamp chamber 6 from the screw support portion 34.

The pair of elastic engaging portions 114 extend toward the 2 nd end portion 104 to the front of the support shaft portion 112. The pair of elastic engagement portions 114 are disposed so as to sandwich the coupling portion 110 therebetween, and extend at a distance from the coupling portion 110 in the 1 st direction Z orthogonal to the axial direction X. Therefore, the pair of elastic engagement portions 114 can be elastically deformed in a direction to approach to and separate from the outer peripheral surface of the coupling portion 110.

When the optical axis adjusting screw 100 is inserted into and inserted through the screw supporting portion 34, the pair of elastic engaging portions 114 are pressed by the inner wall of the screw supporting portion 34 and elastically deformed in a direction approaching the coupling portion 110. When the optical axis adjusting screw 100 enters a position where the sealing member 118 abuts against the inner wall of the screw supporting portion 34, the entire pair of elastic engaging portions 114 pass through the screw supporting portion 34. At this time, the pair of elastic engagement portions 114 elastically return to be displaced in a direction away from the coupling portion 110. In this state, the end of each elastic engagement portion 114 on the lamp rear side abuts against the end of the screw support portion 34 on the lamp front side. This prevents the optical axis adjustment screw 100 from being pulled out of the lamp body 2.

The 2 nd end 104 is provided with a gear portion 120, a 2 nd recess 122, and a 3 rd recess 124. The gear portion 120 protrudes around the shaft at the 2 nd end 104. At least a part of the gear portion 120 is made of metal. The 2 nd recess 122 extends from the end surface of the optical axis adjusting screw 100 on the 2 nd end 104 side toward the 1 st end 102 side. The 2 nd recess 122 extends in the 2 nd end portion 104 to the front of the 1 st recess 116 in the axial direction X of the optical axis adjusting screw 100.

The 3 rd recessed portion 124 extends from the tip of the 2 nd recessed portion 122, in other words, the bottom surface of the 2 nd recessed portion 122 toward the 1 st end portion 102 side. The tip of the 3 rd recess 124 is located on the 1 st end 102 side of the 1 st recess 116. Thus, the 1 st recess 116 is located within the extension of the 3 rd recess 124 in the axial direction X. The 3 rd recess 124 extends at a distance from the 1 st recess 116. That is, the 3 rd recessed portion 124 extends at a position closer to the axial center of the optical axis adjusting screw 100 than the bottom surface of the 1 st recessed portion 116. The optical axis adjusting screw 100 of the present embodiment has 43 rd recesses 124. The 3 rd recessed portions 124 are arranged around the shaft at predetermined intervals.

The outer wall of the 2 nd recess 122 has a shape that matches a tool such as a screwdriver when viewed from the rear side of the lamp. Fig. 2 (B) illustrates a hexagonal outer wall as an example. The 2 nd end portion 104 is fitted with a tool and rotated, whereby the optical axis adjusting screw 100 is rotated. Thereby, the 1 st segment 28 of the bracket portion 18 is conveyed in the direction corresponding to the rotation direction of the optical axis adjusting screw 100, and the lamp unit 8 is tilted with respect to the lamp body 2.

The optical axis adjusting screw 100 has a hollow portion 126 extending from the 1 st end portion 102 over at least a part of the intermediate portion 106. The hollow portion 126 of the present embodiment extends from the 1 st end portion 102 substantially over the entire thread forming portion 108. The hollow portion 126 is open to the outside at the 1 st end portion 102.

(mold apparatus)

Next, a mold apparatus for molding the optical axis adjusting screw 100 will be described. Fig. 4 is a cross-sectional view showing a schematic structure of a mold device according to an embodiment. Fig. 5 is a perspective view showing a schematic structure of a part of the die apparatus. In fig. 5, the detailed portions of the mold and the optical axis adjusting screw are not shown. The mold apparatus 200 has a mold 202. The mold 202 forms a molding space (cavity) 204 corresponding to the optical axis adjusting screw 100 as a resin member by a plurality of molds.

The mold 202 has: a 1 st mold 206 corresponding to the 1 st end portion 102 and the intermediate portion 106 of the optical axis adjusting screw 100; and a 2 nd mold 208 corresponding to the 2 nd end 104. The 1 st die 206 forms a 1 st region 204a of the molding space 204 corresponding to the 1 st end portion 102 and 3 rd to 5 th regions 204c to 204e corresponding to the intermediate portion 106. The 3 rd region 204c is a space corresponding to the thread forming portion 108, the 4 th region 204d is a space corresponding to the coupling portion 110, and the 5 th region 204e is a space corresponding to the support shaft portion 112. A 2 nd region 204b corresponding to the 2 nd end 104 is formed by the 2 nd die 208.

The 1 st mold 206 includes a 1 st portion 210, a 2 nd portion 212, a 3 rd portion 214, a 4 th portion 216, a 5 th portion 218. The parts can be separated from each other. The 1 st part 210 corresponds to the 1 st end 102 side tip of the optical axis adjusting screw 100. The 1 st portion 210 has a gate 220 and a gas injection port 222. The gate 220 and the gas injection port 222 are connected to the 1 st region 204 a. The molten resin is injected into the molding space 204 through the gate 220. Gas is injected into the molding space 204 through the gas injection port 222.

The 2 nd and 3

rd portions

212, 214 each have a recess 224 corresponding to the 1 st and 3

rd regions

204a, 204c, a recess 226 corresponding to the 4 th region 204d, and a recess 228 corresponding to the 5 th region 204 e. In the recessed portion 228 corresponding to the 5 th region 204e, a 1 st projecting portion 230 is provided near the 2 nd region 204 b. The 1 st projection 230 is a portion corresponding to the 1 st recess 116 of the optical axis adjusting screw 100. In addition, each of the 2 nd and 3

rd parts

212, 214 has a pair of flat projections 232. The pair of flat projections 232 are disposed so as to sandwich the recess 226 corresponding to the 4 th region 204d in the 1 st direction Z. Each flat projection 232 is a portion for forming a space between the elastic engagement portion 114 and the coupling portion 110.

The 2 nd and 3

rd parts

212 and 214 have a 1 st receiving recess 234 on the opposite side of the recess 226 with one flat projection 232 therebetween. A space into which the 4 th part 216 is fitted is formed by the 1 st receiving recess 234. The 2 nd and 3

rd parts

212 and 214 have a 2 nd accommodation recess 236 on the opposite side of the recess 226 with the other flat projection 232 therebetween. A space into which the 5 th part 218 is fitted is formed by the 2 nd receiving recess 236.

The 2 nd portion 212 and the 3 rd portion 214 are disposed so as to oppose to each other in the 2 nd direction Y orthogonal to the axial direction X and the 1 st direction Z. The 2 nd part 212 can approach/separate from the 3 rd part 214 in the 2 nd direction Y. The 1 st region 204a, the 3 rd region 204c to the 5 th region 204e are formed by combining the 2 nd part 212 and the 3 rd part 214. In addition, the housing spaces of the 4 th part 216 and the 5 th part 218 are formed.

The 4 th portion 216 and the 5 th portion 218 are disposed opposite in the 1 st direction Z. The 4 th part 216 and the 5 th part 218 each have an engaging part recess 238 for forming the elastic engaging part 114 on an end surface facing the flat projection 232. When the 4 th and 5

th parts

216 and 218 are fitted into the 2 nd and 3

rd parts

212 and 214, the 6 th region 204f of the molding space 204 corresponding to the elastic engaging portion 114 is formed by the flat protrusion 232 and the engaging portion recess 238.

The 2 nd mold 208 includes a 6 th portion 240 and a 7 th portion 242. The parts can be separated from each other. The 6 th part 240 has: a through hole 244 connected to the 5 th region 204 e; and an annular gear groove portion 246 extending around the through hole 244 when viewed in the axial direction X. The gear portion 120 is fitted into the gear groove portion 246.

The 7 th portion 242 has a 2 nd protrusion 248 and a 3 rd protrusion 250. The 2 nd convex portion 248 is a portion corresponding to the 2 nd concave portion 122 of the optical axis adjusting screw 100. The 2 nd convex portion 248 is arranged to overlap the through hole 244 when viewed from the axial direction X, and is projected toward the 1 st region 204a side. The front end of the 2 nd projection 248 is located immediately before the 1 st projection 230 in the axial direction X. That is, the 1 st projection 230 is located on the 1 st region 204a side of the 2 nd projection 248.

The 3 rd convex portion 250 extends from the tip of the 2 nd convex portion 248 toward the 1 st region 204a side. The 3 rd protruding portion 250 passes through the through hole 244 of the 6 th portion 240, and the tip thereof is positioned on the 1 st region 204a side of the 1 st protruding portion 230. Regarding the projecting length of the 3 rd projection 250, a person skilled in the art can appropriately set it in consideration of the possibility of damage or the like at the time of molding if it is excessively long. The 3 rd convex portion 250 extends at a distance from the 1 st concave portion 116. The mold apparatus 200 of the present embodiment has 43 rd convex portions 250. The 3 rd protruding portions 250 are rod-shaped and arranged around the axis with a predetermined interval therebetween. The draft angle of the 3 rd projection 250 is preferably 5 ° or less, more preferably 1 ° with respect to the axial direction X.

In addition, the 7 th part 242 has a gas discharge port 252 for discharging the gas in the molding space 204. The gas discharge port 252 is connected to the 5 th region 204e of the molding space 204, for example, at the substantially center of the distal end surface of the 2 nd convex portion 248. Therefore, the gas discharge port 252 opens into a space surrounded by the plurality of 3 rd convex portions 250.

The 6 th portion 240 and the 7 th portion 242 are disposed to be opposite in the axial direction X. The 6 th segment 240 and the 7 th segment 242 are combined in a state where the metal members constituting the gear portion 120 are placed on the gear groove portion 246 of the 6 th segment 240. Thereby, the metal member constituting the gear portion 120 is sandwiched by the 6 th and 7

th parts

240 and 242.

The number of components constituting each of the 1 st die 206 and the 2 nd die 208, and the position of the optical axis adjusting screw 100 corresponding to each of the 1 st die 206 and the 2 nd die 208 are not particularly limited.

(method for producing resin Member)

Next, a method for manufacturing a resin member using the mold apparatus 200 will be described. Fig. 6 (a), 6 (B), 7 (a) and 7 (B) are views schematically showing a process for producing a resin member. As shown in fig. 6 (a), the plurality of molds are first clamped. At this time, the metal member 128 constituting the gear portion 120 is fitted between the 6 th and 7

th parts

240 and 242. Further, a gas injection nozzle 254 is connected to the gas injection port 222. A vacuum nozzle 256 is connected to the gas outlet 252. A resin injection nozzle, not shown, is connected to the gate 220.

Then, the molten resin 130 is injected from the gate 220 toward the molding space 204 at a predetermined injection pressure while the mold 202 is kept at a predetermined temperature. Thereby, the molten resin 130 is gradually filled in the molding space 204. The air in the molding space 204 is sucked by the vacuum nozzle 256. Examples of the resin include polycarbonate, polypropylene, acrylic, ASA (acrylonitrile-styrene-acrylate), ABS (acrylonitrile-butadiene-styrene), and the like. The resin is injected in a state heated to a predetermined melting temperature.

Next, as shown in fig. 6 (B), after a predetermined amount of the molten resin 130 is filled into the molding space 204, the injection pressure of the molten resin 130 is reduced. This reduces the amount of molten resin 130 supplied. In addition, the gas 258 is injected toward the inside of the molten resin 130 from the gas injection nozzle 254. As the gas 258, nitrogen, air, or the like is used. By injecting the gas 258, the hollow portion 126 is formed inside the molten resin 130.

Then, as shown in fig. 7 (a), the hollow portion 126 is further expanded by increasing the injection pressure of the gas 258. Accordingly, molten resin 130 in molding space 204 moves further in molding space 204, and enters between 1 st convex portion 230 and 3 rd convex portion 250, between 3 rd convex portion 250 and 3 rd convex portion 250, and the like. By sucking air in the molding space 204 by the vacuum nozzle 256, the molten resin 130 can smoothly enter the unfilled region.

Then, as shown in fig. 7 (B), the molten resin 130 is spread to each corner of the molding space 204. The metal member 128 sandwiched between the 6 th part 240 and the 7 th part 242 is integrated with the molten resin 130. After a predetermined time has elapsed, the mold 202 is opened to take out the optical axis adjusting screw 100. Thereby, the optical axis adjusting screw 100 is obtained.

Fig. 8 (a) is a diagram schematically showing the flow of the molten resin in the mold device according to the reference example. Fig. 8 (B) is a diagram schematically showing the flow of the molten resin in the mold device according to the embodiment. In fig. 8 (a) and 8 (B), the areas near the 1 st and 2 nd projections are shown in an enlarged manner. As shown in fig. 8 (a), the mold apparatus 300 according to the reference example does not have the 3 rd convex portion 250 at the tip of the 2 nd convex portion 248.

The molten resin 130 that has entered the 5 th region 204e corresponding to the support shaft portion 112 receives interference from the 1 st projection 230 when passing through the vicinity of the 1 st projection 230 that projects toward the center of the 5 th region 204 e. In the case of the mold apparatus 300 having no 3 rd projecting portion 250, a flow (flow shown by an arrow in the drawing) occurs in which the molten resin 130 travels in the reverse direction, that is, in the direction of returning to the gate 220 side, due to interference of the 1 st projecting portion 230. Thereby, the molten resin 130 stays in the vicinity of the 1 st projection 230, and the molten resin 130 is less likely to enter the 2 nd region 204b corresponding to the 2 nd end 104. In this case, molding defects such as chipping may occur in the 2 nd end portion 104 of the obtained optical axis adjusting screw.

On the other hand, in the mold apparatus 200 according to the embodiment, the 3 rd convex portion 250 protrudes from the tip of the 2 nd convex portion 248 to a position closer to the gate 220 side than the 1 st convex portion 230. Therefore, even if the molten resin 130 that has entered the 5 th region 204e attempts to travel in the direction of returning to the gate 220 side due to interference of the 1 st projection 230, the movement is restricted by the 3 rd projection 250. This suppresses stagnation of the molten resin 130 in the vicinity of the 1 st projection 230, and the molten resin 130 continuously enters the 2 nd region 204 b. Therefore, the possibility of molding failure occurring in the 2 nd end portion 104 of the optical axis adjusting screw can be reduced.

The resin member molded by the mold apparatus 200 is not limited to the optical axis adjusting screw 100. The resin member may be an elongated body having a high aspect ratio and including a 1 st recessed portion 116 disposed near the 2 nd end portion 104 and a 2 nd recessed portion 122 extending from the 2 nd end portion 104 to a position just before the 1 st recessed portion 116. The resin member may be a member used in a device other than the vehicle headlamp device 1.

As described above, the die apparatus 200 according to the present embodiment is an apparatus for molding a resin member that is an elongated body elongated in one direction. The resin member has: the first end 102, the second end 104, a first recess 116 disposed near the first end 104, and a second recess 122 extending in the axial direction of the resin member to a position just before the first recess 116 in the first end 104.

The mold apparatus 200 has a mold 202 forming a molding space 204. The mold 202 has: a gate 220 connected to the 1 st region 204a of the molding space 204 corresponding to the 1 st end portion 102; a 1 st projection 230 disposed near a 2 nd region 204b of the molding space 204 corresponding to the 2 nd end 104; a 2 nd projection 248 disposed in the 2 nd region 204 b; and a 3 rd protrusion 250 extending from the front end of the 2 nd protrusion 248 toward the 1 st region 204 a. The 1 st projection 230 corresponds to the 1 st recess 116, and the 2 nd projection 248 corresponds to the 2 nd recess 122. The tip of the 3 rd convex portion 250 is positioned on the 1 st region 204a side of the 1 st convex portion 230.

In the optical axis adjusting screw 100 as a resin member, a hollow portion 126 may be provided therein from the viewpoint of weight reduction and material reduction. A method of providing a cavity inside the screw 100 for optical axis adjustment includes inserting a gas injection nozzle 254 into the molding space 204 of the mold 202 and injecting gas. Conventionally, the insertion position of the gas injection nozzle 254 is set on the gear portion 120 side of the optical axis adjusting screw 100 from the viewpoint of cost and workability.

Meanwhile, the lamp unit 8 as a support target of the optical axis adjusting screw 100 is increased in size and weight with the increase in functionality. In order to achieve such an increase in size and weight, the optical axis adjusting screw 100 needs to be elongated. This is because if the optical axis adjustment screw 100 is long, the lamp unit 8 can be supported at a position closer to the center of gravity of the lamp unit 8. Further, the optical axis adjustment range can be increased by lengthening the optical axis adjustment screw 100.

However, if the optical axis adjusting screw 100 is long, the hollow portion 126 is also long, and therefore, it is necessary to further transport the gas for providing the hollow portion. In order to extend the gas delivery distance, the diameter of the gas injection nozzle 254 needs to be increased, but if the diameter of the gas injection nozzle 254 is increased, the thickness of a part of the optical axis adjusting screw 100 becomes thinner. When the gas injection nozzle 254 is inserted from the gear portion 120 side, the thickness of the coupling portion 110 of the optical axis adjusting screw 100 becomes thin.

The optical axis adjusting screw 100 is supported by the lamp body 2 at a support shaft 112 continuing from the coupling portion 110. Therefore, by supporting the lamp unit 8, the load applied to the optical axis adjusting screw 100 is concentrated on the connection portion 110. Therefore, the reduction in the thickness of the coupling portion 110 greatly affects the load resistance of the screw 100 for adjusting the optical axis. This is undesirable for reducing the thickness of the coupling portion 110.

Therefore, the present inventors moved the insertion position of the gas injection nozzle 254 to the 1 st end 102 side of the optical axis adjusting screw 100. Thus, the portion with a reduced thickness due to the increased diameter of the gas injection nozzle 254 becomes the 1 st end portion 102. Therefore, a reduction in the load resistance of the optical axis adjusting screw 100 can be avoided.

When the insertion position of the gas injection nozzle 254 is moved to the 1 st end portion 102 side, the gate 220 is desirably disposed also on the 1 st end portion 102 side in order to match the gas delivery direction and the flow direction of the molten resin 130. In this case, the gate 220 is disposed on the opposite side of the 1 st convex portion 230, and the 1 st convex portion 230 corresponds to the 1 st concave portion 116 into which the seal member 118 is fitted. The molding space 204 is narrowed in diameter in the region where the 1 st projection 230 is provided. Therefore, if the molten resin 130 is injected into the molding space 204 from the gate 220, the flow of the molten resin 130 may be disturbed by the 1 st projection 230.

As a result, it may be difficult to fill the 2 nd region 204b at the distal end of the 1 st projection 230 with the molten resin 130. Specifically, the mold 202 has a 2 nd convex portion 248 corresponding to the 2 nd concave portion 122 in the 2 nd region 204 b. Therefore, the width of the flow path of the molten resin 130 in the 2 nd region 204b is narrow, and the inflow of the molten resin 130 into the 2 nd region 204b becomes more difficult.

In contrast, in the mold apparatus 200 according to the embodiment, the 3 rd projecting portion 250 projects from the tip of the 2 nd projecting portion 248. By providing the 3 rd protruding portion 250, the flow of the molten resin 130 disturbed by the 1 st protruding portion 230 is restricted, and the molten resin 130 can be introduced into the 2 nd region 204 b. Therefore, the melted resin 130 can be more reliably filled into the 2 nd region 204 b. Therefore, the occurrence of molding defects in the optical axis adjusting screw 100 can be reduced.

In particular, since the vicinity of the 1 st recess 116 can be prevented from being chipped, the seal member 118 can be brought into close contact with the inner wall of the screw support portion 34 more reliably. This can improve the sealing property at the contact portion between the optical axis adjusting screw 100 and the screw support portion 34.

The optical axis adjusting screw 100 of the present embodiment has a 2 nd recess 122 at the 2 nd end 104. By providing the 2 nd recessed portion 122, the thickness of the 2 nd end portion 104 can be reduced. This can reduce the amount of gas generated from the molten resin 130 in the 2 nd end portion 104, and thus can suppress the generation of voids in the 2 nd end portion 104 and the support shaft portion 112. In particular, since the generation of a void in the vicinity of the 1 st recess 116 can be suppressed, the seal member 118 can be brought into close contact with the inner wall of the screw support portion 34 more reliably.

The optical axis adjusting screw 100 has a hollow portion 126 extending from the 1 st end portion 102 over at least a part of the intermediate portion 106. This can reduce the weight of the optical axis adjusting screw 100. The optical axis adjusting screw 100 has a 3 rd recessed portion 124 extending from the tip of the 2 nd recessed portion 122 toward the 1 st end portion 102. This can further reduce the weight of the optical axis adjusting screw 100.

The present invention is not limited to the above-described embodiments, and various modifications such as design changes can be added based on the knowledge of those skilled in the art, and the embodiments to which the above-described modifications are added are also included in the scope of the present invention. The new embodiment resulting from the combination of the above-described embodiment and modifications has the respective effects of the combined embodiment and modifications.

The 3 rd convex portion 250 may have a shape as in modification 1 and modification 2 below. Fig. 9 (a) is a plan view showing a schematic structure of a 3 rd projection according to modification 1. Fig. 9 (B) is a side view showing a schematic structure of the 3 rd projection according to modification 1. As shown in fig. 9 (a) and 9 (B), the 3 rd convex portion 250 according to modification 1 has a conical shape. Fig. 10 (a) is a plan view showing a schematic structure of a 3 rd projection according to modification 2. Fig. 10 (B) is a side view showing a schematic structure of a 3 rd projection according to modification 2. As shown in fig. 10 (a) and 10 (B), the 3 rd projection 250 according to modification 2 has a circular tube shape.

Claims

1. A mold device for molding a resin member,

the die apparatus is characterized in that the die apparatus,

the resin member is an elongated body elongated in one direction, and has: 1 st end part; a 2 nd end portion opposite to the 1 st end portion; a 1 st recess portion which is disposed near the 2 nd end portion and extends around the axis of the resin member; and a 2 nd recess extending in an axial direction of the resin member to a position just before the 1 st recess in the 2 nd end portion,

the mold device has a mold forming a molding space corresponding to the resin member,

the mold has:

a gate connected to a 1 st region of the molding space corresponding to the 1 st end portion, for injecting a molten resin into the molding space;

a 1 st convex portion disposed near a 2 nd region of the molding space corresponding to the 2 nd end portion, corresponding to the 1 st concave portion;

a 2 nd convex portion arranged in the 2 nd region and corresponding to the 2 nd concave portion; and

a 3 rd convex portion extending from a tip of the 2 nd convex portion toward the 1 st region side, the 3 rd convex portion having a tip located on the 1 st region side of the 1 st convex portion,

the mold has: a 1 st die corresponding to the 1 st end portion and an intermediate portion between the 1 st end portion and the 2 nd end portion; and a 2 nd mold corresponding to the 2 nd end portion,

the 1 st mold has the gate and the 1 st projection,

the 2 nd mold has the 2 nd projection and the 3 rd projection,

the 1 st mould comprises a 1 st part, a 2 nd part, a 3 rd part, a 4 th part and a 5 th part,

the 2 nd and 3 rd parts each have a pair of flat projections,

the 4 th portion and the 5 th portion are disposed to face each other in the 1 st direction, and the 4 th portion and the 5 th portion each have an engaging portion recess for forming an elastic engaging portion on an end face facing the flat convex portion.

2. The mold apparatus of claim 1,

the resin member has a hollow portion extending from the 1 st end portion over at least a part of an intermediate portion between the 1 st end portion and the 2 nd end portion,

the mold has a gas injection port connected to the 1 st region for injecting gas into the molding space.

3. The mold apparatus of claim 1 or 2,

the resin member is an optical axis adjusting screw for adjusting a light emitting direction of the vehicle lamp.

4. A resin member characterized in that,

the resin member is an elongated body elongated in one direction, and has:

1 st end part;

a 2 nd end portion opposite to the 1 st end portion;

an intermediate portion between the 1 st end portion and the 2 nd end portion;

a 1 st recess portion which is disposed near the 2 nd end portion and extends around the axis of the resin member;

a 2 nd recess extending in an axial direction of the resin member to a position just before the 1 st recess in the 2 nd end portion; and

a 3 rd recess extending from a tip of the 2 nd recess toward the 1 st end side, the 3 rd recess having a tip located on the 1 st end side of the 1 st recess,

in the intermediate portion, a thread forming portion, a coupling portion, and a support shaft portion are provided in this order from the 1 st end portion side, and a pair of elastic engagement portions project from an outer peripheral surface of the coupling portion near the 1 st end portion.

5. The resin member according to claim 4, wherein,

the sealing member is fitted into the 1 st recess.

6. The resin member according to claim 4 or 5, wherein,

the resin member is an optical axis adjusting screw for adjusting the light emitting direction of the vehicle lamp.