CN111372747A - 树脂成形品 - Google Patents
树脂成形品 Download PDFInfo
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- CN111372747A CN111372747A CN201880074529.4A CN201880074529A CN111372747A CN 111372747 A CN111372747 A CN 111372747A CN 201880074529 A CN201880074529 A CN 201880074529A CN 111372747 A CN111372747 A CN 111372747A
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- 239000011347 resin Substances 0.000 title claims abstract description 59
- 238000007789 sealing Methods 0.000 claims abstract description 95
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- 239000000463 material Substances 0.000 claims abstract description 70
- 229920003002 synthetic resin Polymers 0.000 claims abstract description 29
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- G01D5/244—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains
- G01D5/245—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains using a variable number of pulses in a train
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Abstract
实现密封性能的可靠性提高。树脂成形品(M)具备:一次成形部(11),由合成树脂材料构成;电线(26),前端部埋设于一次成形部(11)内;传感器(22),在一次成形部(11)内与电线(26)的前端部连接,以部分地露出于一次成形部(11)的外表面的方式配置;密封构件(16),呈筒状,与一次成形部(11)的外周中的比传感器(22)的露出部分(22E)靠后方的区域液密状地密接;及二次成形部(17),与密封构件(16)的外周液密状地密接,并且包围一次成形部(11)中的至少比密封构件(16)靠前方的整个区域。
Description
技术领域
本发明涉及树脂成形品。
背景技术
以往,已知有如下技术,在将一次成形的内部部件设置在模具内之后,将熔融状态的树脂材料填充到模具内,由此成形二次成形部而制造树脂成形品。例如下述专利文献1中,记载有将合成树脂制的板(内部部件)设置在模具内,将熔融状态的树脂材料填充到模具内而成形外装体(二次成形部)的技术。在板的外表面设置有前端形成为尖锐的截面三角形状的熔肋。当熔融状态的树脂材料被填充到模具内时,熔肋的前端侧在树脂材料中熔融,该熔融部分在与树脂材料熔合的状态下固化。由此,在熔肋的前端形成板和外装体密接的密封部,通过密封部能够防止液体浸入。
现有技术文献
专利文献
专利文献1:日本特开2005-7715号公报
发明内容
发明所要解决的课题
在上述的树脂成形品中,在如热冲击试验时那样的反复急剧的加热、冷却的环境下,在内部部件的树脂体和二次成形部的树脂体产生温度差,应力趋向于集中在熔肋前端的密接部分。即,由于在加热时温度先从外侧部上升,在冷却时温度先从外侧部下降,因此在内部部件的树脂体和二次成形部的树脂体之间产生温度差,在外侧部的树脂体和二次成形部的树脂体产生的应变变得不一致。因此,应力会集中于熔肋前端的密接部分。若这样的应力反复在熔肋前端产生,则熔肋前端的密接部分不久将被破坏,在内部部件和二次成形部之间产生间隙,液体可能浸入该间隙。
本发明基于如上所述的情况完成,目的在于实现密封性能的可靠性提高。
解决课题的技术手段
本发明的特征在于,具备:
一次成形部,由合成树脂材料构成;
电线,前端部埋设于所述一次成形部内;
电子部件,在所述一次成形部内与所述电线的前端部连接,以部分地露出于所述一次成形部的外表面的方式配置;
密封构件,呈筒状,与所述一次成形部的外周中的比所述电子部件的露出部分靠后方的区域液密状地密接;及
二次成形部,与所述密封构件的外周液密状地密接,并且包围所述一次成形部中的至少比所述密封构件靠前方的整个区域。
发明效果
由于将一次成形部的外周和二次成形部的内周的间隙液密状地密封的密封构件呈筒状,因此,一次成形部和密封构件的密封区域及密封构件和二次成形部的密封区域在前后方向上确保得较长。因此,密封性能优异。
附图说明
图1是实施例1的树脂成形品的立体图。
图2是一次成形模块的立体图。
图3是表示将包覆电线、传感器及密封构件设置于一次成形用模具的状态的剖视图。
图4是将一次成形部、包覆电线、传感器及密封构件一体化的一次成形模块的剖视图。
图5是表示将一次成形模块设置于二次成形用模具的状态的剖视图。
图6是表示二次成形部成形而与一次成形模块一体化的状态的剖视图。
具体实施方式
本发明的所述密封构件也可以由熔点比所述一次成形部的合成树脂材料低的合成树脂材料构成。根据该结构,在使用模具的一次成形工序中,能够通过一次成形部的熔融树脂材料的热量使密封构件的内周面熔融,使密封构件的内周面与一次成形部的外周面熔接。
本发明的所述密封构件也可以由熔点比所述二次成形部的合成树脂材料低的合成树脂材料构成。根据该结构,在使用模具的二次成形工序中,能够通过二次成形部的熔融树脂材料的热量使密封构件的外周面熔融,使密封构件的外周面与二次成形部的内周面熔接。
本发明的所述密封构件的材料也可以是聚氨酯树脂。根据该结构,即使一次成形部的外周和二次成形部的内周在前后方向上位置偏移,密封构件也不会破损。
<实施例1>
以下,参照图1~图6对将本发明具体化的实施例1进行说明。此外,在以下的说明中,关于前后的方向,将图1~6中的左方定义为前方。关于上下的方向,将在图1~6中出现的朝向照原样定义为上方、下方。
本实施例1的树脂成形品M是安装于车辆的车辆用传感器,具体而言是具有作为用于车轮的转速的测定的车轮速传感器的功能的车辆用传感器。树脂成形品M与和车辆的车轮一体地旋转的转子对置而固定于车辆。树脂成形品M具备合成树脂制的支架10、传感器22(发明内容中记载的电子部件)、线束25和金属制的托架31。托架31作为用于将树脂成形品M安装于车身的单元而发挥功能。
传感器22具有传感器主体23和从传感器主体23向后方悬臂状地延伸的左右一对的连接端子24。传感器主体23具有检测作为对象的物理量(磁场的变化)而转换为电信号的检测元件(图示省略)。传感器主体23通过成形树脂材料将包含检测元件的检测电路(图示省略)液密地密封,从而作为整体形成为板状。传感器22其整体通过嵌件成形埋设于支架10内。当将树脂成形品M固定于车辆时,传感器主体23配置为与车轮的转子(图示省略)的外周面对置。传感器主体23将伴随转子的旋转的磁场的变化转换为电信号,经由连接端子24向线束25输出。
线束25通过利用树脂覆层29等将2根包覆电线26(在发明内容中记载的电线)一并覆盖,由此形成1根线缆。各包覆电线26是利用绝缘包覆层28包围导体27的周知形态。在2根包覆电线26的前端部处为绝缘包覆层28被除去而导体27的前端部露出的状态。2根导体27的露出部通过焊接分别地与一对的连接端子24连接。线束25的后端部与搭载于车辆的控制装置(图示省略)连接。控制装置根据来自传感器22的输出信号计算车辆的车辆速度,进行ABS(防抱死制动系统)等的控制。
支架10具备一次成形部11、密封构件16及二次成形部17而构成,作为整体呈在前后方向上细长的形状。一次成形部11由加入玻璃的聚酰胺树脂(PA)构成,作为整体呈在前后方向上细长的形状。一次成形部11具备形成于其前端部的部件收纳部12、从部件收纳部12的后端向后方延伸的密封功能部13、与密封功能部13的后端相邻的扩径部14及从扩径部14向后方延伸的电线保持部15而构成。
将部件收纳部12以与其前后方向上的轴线为直角进行截断后的截面形状为大概方形。将密封功能部13以与其前后方向上的轴线为直角进行截断后的截面形状为圆形。扩径部14的外径尺寸比密封功能部13大,是呈与密封功能部13同心的圆形的凸缘状的部位。将电线保持部15以与其前后方向上的轴线为直角进行截断后的截面形状为圆形。
传感器22和线束25(2根包覆电线26)的前端部通过嵌件成形与一次成形部11一体化。包含传感器主体23和连接端子24的传感器22的整体埋设于部件收纳部12内,配置于比密封功能部13的前端靠前方。在线束25的前端部处露出了的导体27(与传感器22的连接端子24的连接部分)配置于部件收纳部12内。线束25的前端部中的比与传感器22的连接部分靠后方的区域埋设于密封功能部13、扩径部14及电线保持部15内。
在一次成形工序结束而一次成形部11被成形的状态下,传感器主体23的上表面(传感器22的露出部分22E)为在部件收纳部12的上表面(外表面)处齐平状地露出的状态。传感器22中的露出于一次成形部11的外表面的仅是传感器主体23的上表面(露出部分22E),除传感器主体23的上表面以外埋设于一次成形部11的内部。另外,线束25以从一次成形部11(电线保持部15)的后端面向后方露出的状态导出。由一次成形部11、传感器22及线束25的前端部构成一次成形模块30。
密封构件16由聚氨酯树脂材料构成,是在轴线方向(前后方向)上具有规定的长度尺寸的圆筒形的构件。密封构件16通过嵌件成形与一次成形部11一体化。密封构件16在其全长上相对于密封功能部13的外周面液密状地密接。密封构件16的外径是与扩径部14的外径大致相同的尺寸。密封构件16的后端面相对于扩径部14的前端面液密状地密接。相对于作为一次成形部11的材料的加入玻璃的聚酰胺树脂的熔点为约240℃,作为密封构件16的材料的聚氨酯树脂的熔点为约200℃。即,密封构件16由熔点比一次成形部11的树脂材料低的树脂材料构成。
二次成形部17与一次成形部11相同,由加入玻璃的聚酰胺树脂(PA)构成,通过使用二次成形用模具33的嵌件成形,与一次成形模块30一体化。二次成形部17作为整体在前后方向上细长,呈前端部被封闭的有底筒状。二次成形部17由形成于其前端部的前壁部18、从前壁部18的外周缘向后方延伸的筒状的前部外装部19、从前部外装部19的后端向后方延伸的筒状的中央部外装部20及从中央部外装部20的后端向后方延伸的筒状的后部外装部21构成。
前壁部18与一次成形部11的部件收纳部12的前端面密接。前部外装部19以密接状态覆盖部件收纳部12的外周面的整个区域,并且以密接状态覆盖传感器22的露出部分22E。前部外装部19的后端部外周凸缘状地扩径。中央部外装部20为从前部外装部19中的凸缘状的后端部外周向后方延伸的形态。中央部外装部20以液密状地密接的状态覆盖密封构件16的外周面的整个区域,并且以密接状态覆盖扩径部14的外周面的整个区域。后部外装部21以密接状态覆盖电线保持部15的外周面中的前端侧区域。
接下来,对本实施例1的树脂成形品M的制造方法进行说明。首先,如图3所示,将已连接的状态的线束25的前端部和传感器22设置于一次成形用模具32内。同样地,密封构件16也设置于一次成形用模具32。此时,传感器主体23的露出部分22E与一次成形用模具32以面接触状态抵接,并且密封构件16的外周面的整个区域与一次成形用模具32以面接触状态抵接。在该状态下,将作为一次成形部11的材料的加入玻璃的聚酰胺的熔融材料(以下称为一次成形用熔融树脂材料)注入一次成形用模具32内。
所注入的一次成形用熔融树脂材料(加入玻璃的聚酰胺树脂)的温度为高于240℃的温度,但是该温度比作为密封构件16的材料的聚氨酯树脂的熔点高。通过该温度差,密封构件16中的与一次成形用熔融树脂材料接触的内周面和后端面成为熔融状态,密封构件16中的熔融的部位与一次成形用熔融树脂材料熔合而一体化。此外,密封构件16的外周面的整个区域和前端面由于与温度比一次成形用熔融树脂材料低的一次成形用模具32直接接触,因此不会成为熔融状态。因此,密封构件16相对于一次成形用模具32被定位。
在一次成形用熔融树脂材料填充于一次成形用模具32之后,使一次成形用熔融树脂材料冷却而固化。当一次成形用熔融树脂材料固化时,一次成形部11的成形完成,并且密封构件16的内周面和后端面在相对于一次成形部11的外周液密状地密接的状态下被一体化。另外,传感器22和线束25的前端部在埋设于一次成形部11的状态下被一体化,传感器22的露出部分22E成为露出于一次成形部11的前端部上表面的状态。由此,制造一次成形模块30。
此后,如图5所示,将一次成形模块30和托架31设置于二次成形用模具33内。在该状态下,将作为二次成形部17的材料的加入玻璃的聚酰胺的熔融材料(以下称为二次成形用熔融树脂材料)注入到二次成形用模具33内。所注入的二次成形用熔融树脂材料(加入玻璃的聚酰胺树脂)的温度是高于240℃的温度,但是该温度比作为密封构件16的材料的聚氨酯树脂的熔点高。
通过该温度差,密封构件16中的与二次成形用熔融树脂材料接触的外周面和前端面成为熔融状态,密封构件16中的熔融的部位与二次成形用熔融树脂材料熔合而一体化。此外,密封构件16的内周面的整个区域和后端面由于与冷却后的一次成形部11密接,因此不会成为熔融状态。因此,密封构件16不会相对于一次成形部11发生位置偏移。
在二次成形用熔融树脂材料填充于二次成形用模具33之后,使二次成形用熔融树脂材料冷却而固化。当二次成形用熔融树脂材料固化时,二次成形部17的成形完成,并且密封构件16的外周面和前端面在相对于二次成形部17的内周液密状地密接的状态下被一体化。密封构件16和包含一次成形部11的一次成形模块30在埋设于二次成形部17的状态下被一体化。另外,通过二次成形部17以密接状态覆盖在一次成形部11的前端部上表面处露出的传感器22的露出部分22E。由此,树脂成形品M的制造完成。
在一次成形模块30中,传感器22的露出部分22E露出于一次成形部11的外表面,但传感器22的露出部分22E由一次成形部11覆盖。由于二次成形部17呈前端部利用前壁部18被封闭的有底筒状,因此二次成形部17的后端部内周和一次成形部11的外周的界面面向于树脂成形品M的外部的位置成为允许来自树脂成形品M的外部的水的浸入的浸水允许口。该浸水允许口位于比传感器22的露出部分22E靠后方处。
作为其对策,在比传感器22的露出部分22E靠后方的区域配置密封构件16,通过该密封构件16将二次成形部17的内周面和一次成形部11的外周面的间隙液密状地密封。密封构件16呈在前后方向(从浸水允许口至传感器22的露出部分22E的方向)上具有规定尺寸的圆筒形。因此,密封构件16的外周面和二次成形部17内周面之间的前后方向上的密接区域(液密区域)及密封构件16的内周面和一次成形部11的外周面之间的前后方向上的密接区域(液密区域)被确保得较长。由此,能够在密封构件16处可靠地阻止从树脂成形品M的外部向传感器22的露出部分22E的水的浸入。
如上所述,本实施例1的树脂成形品M具备由合成树脂材料构成的一次成形部11、前端部埋设于一次成形部11内的包覆电线26、传感器22、密封构件16及二次成形部17。传感器22在一次成形部11内与包覆电线26的前端部连接,以部分地露出于一次成形部11的外表面的方式配置。密封构件16呈筒状,与一次成形部11的外周中的比传感器22的露出部分22E靠后方的区域液密状地密接。二次成形部17与密封构件16的外周液密状地密接,并且包围一次成形部11中的至少比密封构件16靠前方的整个区域。
由于将一次成形部11的外周和二次成形部17的内周的间隙液密状地密封的密封构件16呈在前后方向上长的筒状,因此一次成形部11和密封构件16的密封区域及密封构件16和二次成形部17的密封区域在前后方向上被确保得较长。因此,密封性能优异,能够可靠地防止向传感器22的露出部分22E的浸水。
另外,密封构件16由熔点比一次成形部11的合成树脂材料低的合成树脂材料构成。由此,在使用一次成形用模具32的一次成形工序中,通过一次成形用熔融树脂材料的热量使密封构件16的内周面熔融,熔融的密封构件16的内周面与一次成形部11的外周面熔接。因此,能够同时执行使一次成形部11成形的工序和使密封构件16与一次成形部11密接的工序。
另外,密封构件16由熔点比二次成形部17的合成树脂材料低的合成树脂材料构成。由此,在使用二次成形用模具33的二次成形工序中,通过二次成形用熔融树脂材料的热量使密封构件16的外周面熔融,熔融的密封构件16的外周面与二次成形部17的内周面熔接。因此,能够同时执行使二次成形部17成形的工序和使密封构件16与二次成形部17密接的工序。
另外,本实施例1的树脂成形品M的一次成形部11和二次成形部17为相同材料(加入玻璃的聚酰胺树脂),但是在外部气温急剧地变化的情况下,由于一次成形部11和二次成形部17之间的温度差,一次成形部11的外周和二次成形部17的内周在前后方向上发生位置偏移,其结果,密封构件16有可能导致剪断等的破损。在此,在本实施例1中,使密封构件16的材料为聚氨酯树脂。由于聚氨酯树脂具有较高的韧性,因此密封构件16不会破损。
<其他的实施例>
本发明不限定于通过上述记述及附图说明的实施例,例如如下的实施例也包含于本发明的技术范围。
(1)在上述实施例1中,密封构件由熔点比一次成形部低的合成树脂材料构成,但是密封构件的材料也可以是熔点与一次成形部相同的合成树脂,也可以是熔点比一次成形部高的合成树脂。
(2)在上述实施例1中,密封构件由熔点比二次成形部低的合成树脂材料构成,但是密封构件的材料也可以是熔点与二次成形部相同的合成树脂,也可以是熔点比二次成形部高的合成树脂。
(3)在上述实施例1中,使密封构件的材料为聚氨酯树脂,但是密封构件的材料也可以是除聚氨酯树脂以外的合成树脂。
(4)在上述实施例1中,使密封构件为合成树脂制,但是密封构件的材料不限于合成树脂,也可以是金属。
(5)在上述实施例1中,使一次成形部的材料为加入玻璃的聚酰胺树脂(PA),但是一次成形部的材料也可以是除加入玻璃的聚酰胺树脂以外的合成树脂材料。
(6)在上述实施例1中,使二次成形部的材料为加入玻璃的聚酰胺树脂(PA),但是二次成形部的材料也可以是除加入玻璃的聚酰胺树脂以外的合成树脂材料。
(7)在上述实施例1中,使一次成形部和二次成形部为同一材料,但是一次成形部的材料和二次成形部的材料也可以不同。
标号说明
M…树脂成形品
11…一次成形部
16…密封构件
17…二次成形部
22…传感器(电子部件)
22E…传感器的露出部分
26…包覆电线(电线)
Claims (4)
1.一种树脂成形品,其特征在于,
所述树脂成形品具备:
一次成形部,由合成树脂材料构成;
电线,前端部埋设于所述一次成形部内;
电子部件,在所述一次成形部内与所述电线的前端部连接,以部分地露出于所述一次成形部的外表面的方式配置;
密封构件,呈筒状,与所述一次成形部的外周中的比所述电子部件的露出部分靠后方的区域液密状地密接;及
二次成形部,与所述密封构件的外周液密状地密接,并且包围所述一次成形部中的至少比所述密封构件靠前方的整个区域。
2.根据权利要求1所述的树脂成形品,其特征在于,
所述密封构件由熔点比所述一次成形部的合成树脂材料低的合成树脂材料构成。
3.根据权利要求1或权利要求2所述的树脂成形品,其特征在于,
所述密封构件由熔点比所述二次成形部的合成树脂材料低的合成树脂材料构成。
4.根据权利要求1至权利要求3中任一项所述的树脂成形品,其特征在于,
所述密封构件的材料为聚氨酯树脂。
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