CN112984459A - Two-color molded article and two-color molding method - Google Patents
Two-color molded article and two-color molding method Download PDFInfo
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- CN112984459A CN112984459A CN202011486464.XA CN202011486464A CN112984459A CN 112984459 A CN112984459 A CN 112984459A CN 202011486464 A CN202011486464 A CN 202011486464A CN 112984459 A CN112984459 A CN 112984459A
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- light
- transmitting portion
- color
- molding
- transmitting
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- 238000000465 moulding Methods 0.000 title claims abstract description 91
- 238000000034 method Methods 0.000 title claims abstract description 28
- 239000011347 resin Substances 0.000 claims abstract description 25
- 229920005989 resin Polymers 0.000 claims abstract description 25
- 238000001746 injection moulding Methods 0.000 claims abstract description 10
- 230000002093 peripheral effect Effects 0.000 claims description 18
- 230000005540 biological transmission Effects 0.000 claims description 7
- 230000000694 effects Effects 0.000 description 8
- 238000001816 cooling Methods 0.000 description 7
- 238000002156 mixing Methods 0.000 description 3
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 229920005668 polycarbonate resin Polymers 0.000 description 2
- 239000004431 polycarbonate resin Substances 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000008602 contraction Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
- F21S41/25—Projection lenses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0025—Preventing defects on the moulded article, e.g. weld lines, shrinkage marks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1615—The materials being injected at different moulding stations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
- F21S41/24—Light guides
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/40—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by screens, non-reflecting members, light-shielding members or fixed shades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/20—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by refractors, transparent cover plates, light guides or filters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/20—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by refractors, transparent cover plates, light guides or filters
- F21S43/235—Light guides
- F21S43/236—Light guides characterised by the shape of the light guide
- F21S43/241—Light guides characterised by the shape of the light guide of complex shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C2045/1682—Making multilayered or multicoloured articles preventing defects
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
- F21W2107/00—Use or application of lighting devices on or in particular types of vehicles
- F21W2107/10—Use or application of lighting devices on or in particular types of vehicles for land vehicles
Abstract
The invention provides a two-color molded article molded with high precision and a two-color molding method in which the amount of deformation during molding is suppressed. The present invention provides a two-color molded article comprising: a light-transmitting portion which is composed of a light-transmitting resin member and has a surface to which fine irregularities are applied by injection molding; and a non-light-transmitting portion that is formed of a colored member and extends so as to surround the outer periphery of the light-transmitting portion without being laminated in the plate thickness direction with the light-transmitting portion, wherein the non-light-transmitting portion is a primary molded product, and the light-transmitting portion is molded integrally with the non-light-transmitting portion as a secondary molded product by being in close contact with the non-light-transmitting portion. Since the non-light-transmitting portion disposed on the outer side is first molded into a frame shape as a primary molded article, deformation of the light-transmitting portion secondarily molded on the inner side of the non-light-transmitting portion is suppressed, and the light-transmitting portion itself and the minute irregularities on the surface thereof are molded with high accuracy.
Description
Technical Field
The present invention relates to a two-color molding, and more particularly to a two-color molding method for an injection-molded article in which a light-transmitting portion and a non-light-transmitting portion having a microfabricated portion on the surface are integrally molded.
Background
For example, a two-color molding method of a two-color molded article 900, as shown in fig. 7, in which a light-transmitting portion 901 made of a light-transmitting resin member and having a surface processed by injection molding applied to the surface thereof and a non-light-transmitting portion 902 made of a colored member extending from the peripheral edge of the light-transmitting resin member are integrally molded, will be described with reference to fig. 8A to 8D.
Such a two-color molding material is first molded from the light-transmitting portion 901 disposed inside. As shown in fig. 8A, the fixed mold 903 and the primary movable mold 904 are clamped, and a light-transmitting resin member is injected into the molding space, thereby molding a light-transmitting portion 901 as a primary molded article. In addition, fine irregularities for guiding the incident light are formed on the surface thereof.
Next, as shown in fig. 8B, the mold is opened, and the movable mold 904 is separated once.
Next, as shown in fig. 8C, the fixed die 903 and the secondary movable die 905 are closed, and the colored resin member is injected into the molding space to mold the non-light-transmitting portion 902 as an overmolding.
Documents of the prior art
Patent document
Patent document 1: japanese Kokai publication 2014-175204
Patent document 2: japanese patent laid-open No. 2013-37963
Disclosure of Invention
Problems to be solved by the invention
However, in the case of such a two-color molding method, when the movable mold 904 is removed once, the light-transmitting portion 901 is deformed due to cooling and shrinkage, and both ends are lifted (see fig. 8D). In order to suppress this deformation, the non-light-transmitting portion 902 is molded in a state forcibly suppressed by the secondary movable mold 905, and the light-transmitting portion 901 disposed inside is further deformed due to the deformation caused by cooling and contraction of the large-sized and large-sized non-light-transmitting portion 902. There is a problem that the translucent portion 901 is deformed beyond an allowable range, and the appearance is damaged. Further, since the fine irregularities on the surface of the light transmitting portion 901 are also flattened, there is a problem that a problem occurs in guiding the incident light.
The present invention has been made in view of the above circumstances, and provides a two-color molded article molded with high accuracy and a two-color molding method in which the amount of deformation during molding is suppressed.
Means for solving the problems
In order to achieve the above object, one aspect of the two-color molded article according to the present disclosure includes: a light-transmitting portion which is composed of a light-transmitting resin member and has a surface to which fine irregularities are applied by injection molding; and a non-light-transmitting portion that is formed of a colored member and extends so as to surround the outer periphery of the light-transmitting portion without being laminated in the plate thickness direction, wherein the non-light-transmitting portion is a primary molded product, and the light-transmitting portion is molded integrally with the non-light-transmitting portion as a secondary molded product in close contact with the non-light-transmitting portion.
According to this aspect, although the end portion is warped when the mold is opened when the light-transmitting portion is molded as a primary molded article, the non-light-transmitting portion disposed on the outer side is formed as a primary molded article first, so that deformation during molding of the light-transmitting portion disposed on the inner side is suppressed, and fine irregularities on the entire surface are molded with high accuracy. The surface of the light-transmitting portion can be provided with fine irregularities over the entire surface thereof without pressing the surface with a secondary molding die.
In one aspect, a part of the non-light-transmitting portion surrounding the light-transmitting portion is notched, an outward protruding portion of the light-transmitting portion is engaged with the notched portion and is in close contact therewith, and a gate mark for injection molding is provided on an end surface of the outward protruding portion exposed to be flush with an outer peripheral surface of a side edge portion of the two-color mold.
According to this aspect, since the gate portion of the light-transmitting portion is exposed on the outer peripheral surface of the two-color mold, the light-transmitting resin member is not injected so as to be laminated with the non-light-transmitting portion, and color mixing during molding is prevented.
In one aspect, linear ribs extending in the circumferential direction are formed to protrude continuously or discontinuously on the inner sides of the leg portions provided at the outer and inner peripheral edges of the non-light-transmitting portion.
According to this aspect, the linear rib is undercut, and the large-volume and large-size non-light-transmitting portion disposed outside catches the molding die at the time of primary molding to suppress deformation of the molded article, so that the non-light-transmitting portion is molded with high accuracy.
In one aspect, the leg portion is provided with a plurality of parallel linear ribs.
If a plurality of linear ribs are provided, deformation during molding is suppressed accordingly, and therefore the non-light-transmitting portion is molded with higher accuracy.
In one embodiment, the maximum protruding amount of the linear rib is set to be within 0.5 mm.
According to this aspect, since the amount of protrusion of the undercut into the molding die is extremely small, the effect of preventing deformation is obtained, and the non-design portion can be die-cut as usual without providing a complicated die such as a split die.
In one embodiment, the linear rib is provided on the two-color molded article having a step angle of 45 degrees or more. When the drop angle of the two-color molded article is 45 degrees or more, the molded article becomes a three-dimensional large-sized molded article, and therefore deformation during molding due to cooling shrinkage is also large. In such a case, the effect of suppressing deformation of the linear rib is particularly preferable.
In one embodiment, the fine unevenness is provided over the entire surface of the surface. In another aspect, the fine unevenness is further provided on a back surface of the light transmitting portion.
Further, as one aspect of the two-color molding method, there is provided a method of molding a two-color molded article, the two-color molded article including: a light-transmitting portion formed of a light-transmitting resin member, the surface of which is provided with fine irregularities by injection molding; and a non-light-transmitting portion that is formed of a colored member and extends so as to surround the outer periphery of the light-transmitting portion without being laminated with the light-transmitting portion in the plate thickness direction, the two-color molding method including: a primary molding step of molding the frame-shaped non-light-transmitting portion by closing a fixed-side mold and a primary movable-side mold and injecting a colored resin member into a first molding space defined by the fixed-side mold and the primary movable-side mold; and a secondary molding step of integrally molding the light-transmitting portion, which is not laminated in a thickness direction with the non-light-transmitting portion, inside the non-light-transmitting portion by closing the fixed-side mold and the secondary movable-side mold while holding the non-light-transmitting portion, and injecting a light-transmitting resin member into a second molding space defined by the mold closing.
According to this molding method, since the non-light-transmitting portion arranged in a frame shape on the outer side is molded at one time, the light-transmitting portion arranged on the inner side is not affected by deformation due to cooling shrinkage of the non-light-transmitting portion at the time of molding, and deformation at the time of molding is suppressed.
Effects of the invention
As is apparent from the above description, the present invention provides a two-color molded article molded with high accuracy and a two-color molding method in which the amount of deformation during molding is suppressed.
Drawings
Fig. 1A is a front view of a two-color molded article (inner lens unit) according to a first embodiment, and fig. 1B is a cross-sectional view.
Fig. 2A is a front perspective view of the two-color molded article (inner lens unit) according to the first embodiment, and fig. 2B is a rear perspective view.
Fig. 3 is a flowchart of a method of molding a two-color molded article (inner lens unit) according to the first embodiment.
Fig. 4-1A to 4-1C are explanatory views of a method of molding a two-color molded article (inner lens unit) according to the first embodiment.
Fig. 4-2D to 4-2F are explanatory views of a method of molding a two-color molded article (inner lens unit) according to the first embodiment.
Fig. 5 is a perspective view of a two-color molded article (outer lens unit) according to a second embodiment.
Fig. 6 is a cross-sectional view of a two-color molded article (outer lens unit) according to a second embodiment.
Fig. 7 is a front view of a conventional two-color molded article.
Fig. 8A to 8D are explanatory views of a method of molding a conventional two-color molded article and problems thereof.
Description of the reference numerals
1: an inner lens unit (two-color molded member); 2. 102: an outer peripheral surface; 3. 103: a bonding surface; 10. 110: a light-transmitting portion; 110 a: a protruding portion; 11: a surface; 12: a back side; 13. 14: tiny bumps and dips; 20. 120: a non-light-transmitting portion; 120 a: a cut-out portion; 21. 22: a leg portion; 23: a micro-rib; 40: a fixed side mold; 50: a primary movable-side mold; 60: a secondary movable-side mold; 101: an outer lens unit (two-color molded member); g: gate mark; DR1, DR 2: stripping direction; h: a height; s101 to S105: a step of; s1, S2: a forming space; α: the fall angle.
Detailed Description
Hereinafter, preferred embodiments of the present invention will be described 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 essential to the invention. In the drawings, the ratio of the thickness, width, and length of each member does not reflect an actual ratio, but schematically shows the content of the structure.
(first embodiment)
Fig. 1A and 1B, and fig. 2A and 2B show an inner lens unit 1 as a two-color molded article according to a first embodiment of the present invention, and fig. 1A, 1B, 2A and 2B show a front view, a transverse sectional view, a front perspective view and a rear perspective view, respectively.
The inner lens unit 1 is a two-color molded article in which a translucent portion 10 constituting an inner lens and a non-translucent portion 20 constituting an extension portion are integrally molded, and is disposed in front of a light emitter in a lamp chamber of a vehicle lamp.
The inner lens unit 1 is an example of the embodiment, and if a translucent portion having translucency and a non-translucent portion extending by being closely contacted to the outer periphery of the translucent portion and having non-translucency are integrally molded, the structure and the two-color molding method of the present invention can be applied to a two-color molded product such as a light guide and an extension portion, a cover lens and a light shielding wall of a stop lamp, an inner lens of a warning lamp, and a mounting portion thereof.
The light-transmitting portion 10 is disposed at the center of the inner lens unit 1, is made of a light-transmitting resin member such as a polycarbonate resin or a polymethyl methacrylate resin, and has light-transmitting properties. In the present embodiment, the light transmitting portion 10 is transparent, but may be colored as long as it has a property of transmitting light.
Further, since the minute unevenness 13, 14 is applied to the edges of the front surface 11 and the back surface 12, there is no light leakage from the outer edge of the light transmitting portion 10, and the connection with the non-light transmitting portion 20 is natural, giving a high-grade impression.
The non-light-transmitting portion 20 extends in a band shape with a predetermined width on the outer periphery of the light-transmitting portion 10 so as to surround the light-transmitting portion 10. The non-light-transmitting portion 20 is an extension of the shielding member, and is formed of a colored resin member that is not light-transmitting, such as a colored polycarbonate resin or a colored polyester resin. The non-light-transmitting portion 20 forms the outer periphery of the inner lens unit 1, and is disposed in a frame shape on the outer peripheral portion of the light-transmitting portion 10, and is integrated with the light-transmitting portion 10.
On the rear surface side of the outer periphery of the light transmitting portion 10 and the inner periphery of the non-light transmitting portion 20, which is a joint portion of the light transmitting portion 10 and the non-light transmitting portion 20, a first leg portion 15 is provided as a peripheral wall on the light transmitting portion 10 and a second leg portion 21 is provided on the non-light transmitting portion 20, respectively, over the entire periphery. Further, the third leg portion 22 is similarly provided on the outer periphery of the inner lens unit 1 (the outer periphery of the non-light-transmitting portion 20).
Inside the second leg portion 21 and the third leg portion 22 of the non-light-transmitting portion 20, a minute rib 23 is provided so as to protrude. The minute ribs 23 are minute protrusions having a height H (the maximum projection amount from each leg) of 0.5mm or less and a width W of about 1mm or less, and are linearly provided along the outer circumferential direction. One continuous minute rib 23 is provided on the second leg portion 21, and two parallel minute ribs 23 are provided discontinuously along the peripheral edge on the third leg portion 22.
In general, a molded article having a large outer shape and volume itself is also largely contracted and deformed when cooled, and the minute ribs 23 provided on the second leg portion 21 and the third leg portion 22 of the non-light-transmitting portion 20 are caught as undercuts by the molding die when the non-light-transmitting portion 20 is cooled, and play a role of suppressing deformation of the non-light-transmitting portion 20. Therefore, the inner lens unit 1 is molded with high accuracy.
The minute ribs 23 are undercuts protruding substantially perpendicularly to the die-drawing direction DR1, and are extremely small in height H and width W, and therefore can be easily taken out from the molding die. Since the projection is linearly provided along the outer circumferential direction even if the projection amount is extremely small, the effect of suppressing the deformation is excellent. The number of the micro ribs 23 provided on the second leg portion 21 and the third leg portion 22 is not limited, and it is not further limited whether they are continuous or discontinuous. Since the minute ribs 23 are provided inside the inner lens unit 1, there is no influence on the appearance.
The transparent portion 10 and the non-transparent portion 20 are not laminated in the thickness direction, and the cross section of the joint surface 3 dividing the two appears as a straight line.
In order to facilitate removal from the mold after molding, any one of the four surfaces of the outer peripheral surface 2 of the inner lens unit 1 is slightly inclined inward from the back surface side toward the front surface side. In contrast, the joint surface 3 is inclined in the direction opposite to the outer peripheral surface 2.
This is because the non-light-transmitting portion 20 is a primary molded article, and therefore the joint surface 3 is formed to be inclined with respect to the mold lifting direction DR1 as described above (details will be described later) so that the primary mold can be easily removed. The inner lens unit 1 is molded by performing secondary molding of the light transmitting portion 10 so that the non-light transmitting portion 20 as a primary molded product is fitted therein.
The inner lens unit 1 configured as described above is less deformed during molding, and the fine irregularities 13 and 14 are molded with high accuracy over the entire surfaces of the front surface 11 and the back surface 12 of the light transmission section 10, and the appearance of the fine irregularities 13 and 14 is conspicuous. Further, the light transmitting portion 10 as the inner lens and the non-light transmitting portion 20 as the extension portion are integrated, so that the number of components can be reduced, and the assembly efficiency can be improved.
(two-color Molding method)
A two-color molding method of the inner lens unit 1 configured as described above will be described. Fig. 3 is a flow chart of a two-color molding method. Fig. 4-1A to 4-1C and 4-2D to 4-2F are schematic diagrams showing a schematic configuration of a molding die, and are explanatory views of steps of a two-color molding method. The two-color molding method will be described in detail in accordance with the respective steps with reference to fig. 4-1A to 4-1C and 4-2D to 4-2F along the flowchart of fig. 3.
First, in step S101, as shown in fig. 4-1A, the fixed die 40 and the primary movable die 50 are arranged in a state of facing each other and are clamped. Since the opaque portion 20 is molded as a single-molded article first, the mold is closed to define a molding space S1 corresponding to the shape of the opaque portion 20 inside the mold.
In the present embodiment, the back surface side and the front surface side of the inner lens unit 1 are molded by the molding surface of the fixed mold 40 and the molding surfaces of the primary movable mold 50 and the secondary movable mold 60, respectively.
The molding surface of the fixed die 40 is provided with a minute recess 43 recessed substantially perpendicularly to the die-cutting direction DR 1. The mold-drawing direction DR1 is a direction in which the inner lens unit 1 is separated from the fixed-side mold 40, and is a direction in which the primary movable-side mold 50 is separated. The minute recessed portion 43 is a member for molding the minute rib 23.
Next, in step S102, as shown in fig. 4-1B, the colored resin member heated to the predetermined melting temperature is injected into the molding space S1, and the frame-shaped opaque portion 20 is molded as a primary molded article.
Next, in step S103, as shown in fig. 4-1C, the non-light-transmitting portion 20 is cooled, and then the mold is opened, and the primary movable mold 50 is separated.
Next, in step S104, as shown in fig. 4 to 2D, the secondary movable die 60 is clamped to the fixed die 40 instead of the primary movable die 50. Since the light transmitting portion 10 is formed as a secondary mold by concentration molding, a molding space S2 corresponding to the shape of the light transmitting portion 10 is defined in the mold so that the non-light transmitting portion 20 as a primary mold is fitted into the mold after mold clamping.
Next, in step S105, as shown in fig. 4 to 2E, the translucent resin member heated to the predetermined melting temperature is injected into the molding space S2, and the translucent portion 10 is molded inside the non-translucent portion 20. Thereby, the non-light-transmitting portion 20 and the light-transmitting portion 10 are integrally molded.
Next, in step S106, as shown in fig. 4 to 2F, the mold is opened, and the inner lens unit 1 is removed from the mold. First, the secondary movable mold 60 is separated, and the inner lens unit 1 is removed from the fixed mold 40. Although the fixed mold 40 is provided with the minute recessed portions 43 as undercuts, since the recessed amount thereof corresponds to the minute ribs 23 and is about 0.5mm at maximum, the inner lens unit 1 can be removed in a state of being held by the ejector pins (not shown) from the fixed mold 40.
(Effect)
The operation and effect of the inner lens unit 1 molded by the above molding method will be described in comparison with the conventional two-color molding member 900 shown in fig. 7 and the conventional two-color molding method shown in fig. 8A to 8D.
As shown in fig. 7 and fig. 8A to 8D, in the conventional molding method, since the transparent portion 901 disposed inside as a primary mold is molded first, when the opaque portion 902 as an outside secondary mold is cooled, the transparent portion 901 is also deformed integrally with the primary mold, and thus there is a problem that the amount of deformation of the transparent portion 901 becomes extremely large.
In contrast, in the inner lens unit 1, since the non-light-transmitting portion 20 disposed on the outer side is used as the primary molded product, the light-transmitting portion 10 as the secondary molded product is not affected by cooling shrinkage of the non-light-transmitting portion 20, and therefore, the deformation amount is relatively small and molding is performed with high accuracy. Further, the minute ribs 23 reduce the amount of deformation of the non-light-transmitting portion 20 itself, and the entire inner lens unit 1 is less deformed, thereby enabling high-precision molding.
Further, when the light transmitting portion 901 is subjected to surface processing as in the case of the conventional two-color molding 900, the light transmitting portion 901 is warped due to cooling shrinkage when molded once, and the end portion is warped (see fig. 8D), so that the molding accuracy is poor. In particular, there is a problem that a desired light distribution cannot be obtained because minute irregularities of the surface processing are damaged.
In the inner lens unit 1, since the light transmitting portion 10 is a two-shot molding, the light transmitting portion 10 is cooled by being integrated with the non-light transmitting portion 20, and therefore such a phenomenon does not occur. Therefore, the entire light transmission section 10 and the minute convexities and concavities 13 and 14 are molded with high accuracy.
Further, in the conventional secondary movable mold 905, it is necessary to provide a pressing portion 907 protruding above the light transmitting portion 901 (see fig. 8C), and it is not possible to provide fine irregularities to the front end portion of the light transmitting portion 901 (see fig. 7). The light-transmitting portion 901 has a problem that light leakage occurs from an edge portion to which fine unevenness is not applied, and design properties are impaired.
In the inner lens unit 1, since the light transmitting portion 10 is formed by the secondary molding, the fine irregularities 13 and 14 can be applied to the entire surfaces of the front surface 11 and the back surface 12 of the light transmitting portion 10, and a new optical appearance can be provided by the fine irregularities 13 and 14 on both surfaces.
(drawing direction)
The inner lens unit 1 includes a non-light-transmitting portion 20 as a primary molded article. In general, the molding order of a primary molded article or a secondary molded article of a two-color molded article is grasped by a slope direction or the like with respect to a mold-drawing direction of the molded article. The mold drawing direction is a direction in which the movable-side mold and the molded article are separated from the fixed-side mold. In order to enable removal of the movable mold and the molded article, the convex portions of the molding surface of the fixed mold are all formed at a positive inclination with respect to the mold-drawing direction, and the outer peripheral surfaces of the two-color molded article and the primary molded article are also formed at a positive inclination with respect to the mold-drawing direction. Further, the mold-drawing direction, the molding order, and other characteristics of the two-color molded article are grasped by the ejector pin traces, the positions and the directions in which the leg portions are provided, and the like.
In the inner lens unit 1, since the joint surface 3 is inclined outward, unlike the outer peripheral surface 2, the non-light-transmitting portion 20 is grasped as a primary molded product (in the case where the light-transmitting portion is a primary molded product, the joint surface 906 is inclined inward as in the light-transmitting portion 901 shown in fig. 8C).
(second embodiment)
Fig. 5 is a perspective view of the outer lens unit 101 according to the second embodiment of the present invention. Fig. 6 is a sectional view of the outer lens unit 101.
The outer lens unit 101 constitutes a part of a housing of the vehicle headlamp, and is a two-color molded product in which a light-transmitting portion 110 as an outer lens for transmitting light of the headlamp and a non-light-transmitting portion 120 as a cover member are integrated. The inner lens unit 1 is elongated and largely curved as a whole, as compared with the inner lens unit 1 according to the first embodiment. In addition, as in the first embodiment, the fine processing is applied to the entire surface of the front surface and the back surface of the light transmitting portion 110, but the fine processing is not illustrated in fig. 5 and 6.
The non-light-transmitting portion 120 extends in a band shape along the outer peripheral portion of the light-transmitting portion 110, and includes a notch portion 120a at only one position. The light transmitting portion 110 includes an extending portion 110a that is integrally joined to the notch portion 120 a. The protruding portion 110a is exposed so as to be flush with the outer peripheral surface 102 of the side edge portion of the outer lens unit 101, and further has a gate mark G for injection molding at the exposed end portion.
This is because the gate portion is provided in the laminated portion laminated with the non-light-transmitting portion so that the gate mark is not exposed to the surface when the light-transmitting resin member is injection-molded, but by exposing the gate portion of the light-transmitting portion 110 to the outer peripheral surface of the outer lens unit 101 in this way, the light-transmitting resin member can be directly injected without providing the laminated portion laminated with the non-light-transmitting portion 120. Color mixing can be prevented when the melted light-transmitting resin member for secondary molding is injected and passes through the laminated part of the colored resin members formed in one step. This can prevent a functional deterioration due to a poor appearance of the secondary molded article and a reduction in light transmittance caused by color mixing.
As shown in fig. 6, in the transparent portion 110 and the non-transparent portion 120, as in the first embodiment, a first leg portion 115 and a second leg portion 121 are provided on the back surface side of the joint portion between the two over the entire circumference. Further, a third leg portion 122 is also provided on the outer periphery of the outer lens unit 101 (the outer periphery of the non-light-transmitting portion 120). In the present embodiment, the minute ribs 123 are provided in parallel at two positions only in the third leg portion 122.
The outer lens unit 101 (the non-light-transmitting portion 120) has a large step angle α and is configured to be higher up and down than the depth. The drop angle α is a drop angle from the horizontal to the other end with respect to the upper end in an arbitrary cross section of the molded article, and tends to increase when the minimum curvature of the surface of the molded article becomes smaller or the drop angle α becomes longer vertically.
When the drop angle α is large, a large three-dimensional molded product is obtained, and therefore the molding deformation amount is also increased by three-dimensional deformation due to cooling shrinkage. Therefore, when the difference angle α is large, particularly in a large-sized molded product having a difference angle α of 45 degrees or more like the non-light-transmitting portion 120, the effect of suppressing deformation by the fine ribs 123 is large.
The mold-release direction DR2 of the outer lens unit 101 is an upward direction, which is grasped by the inclination of the outer peripheral surface 102. Since the non-light-transmitting portion 120 is a primary molded product, the bonding surface 103 is inclined outward with respect to the die-drawing direction DR2 (in the case where the light-transmitting portion 110 is a primary molded product, the bonding surface is inclined inward as indicated by a two-dot chain line in fig. 6). As in the first embodiment, the translucent portion 110 is secondarily molded so that the translucent portion 120 as a primary mold is fitted therein. Therefore, deformation of the light transmitting portion 110 is suppressed, and the outer lens unit 101 is molded with high accuracy.
Although the preferred embodiment and the modified examples of the present invention have been described above, the above embodiment is an example of the present invention, and these embodiments can be combined based on the knowledge of those skilled in the art, and such an embodiment is also included in the scope of the present invention.
Claims (9)
1. A two-color molding is characterized in that,
the two-color molded article is provided with:
a light-transmitting portion which is composed of a light-transmitting resin member and has a surface to which fine irregularities are applied by injection molding; and
a non-light-transmitting portion which is formed of a colored member and extends so as to surround the outer periphery of the light-transmitting portion without being laminated with the light-transmitting portion in the plate thickness direction,
the non-light-transmitting part is a primary molded part, and the light-transmitting part is molded integrally with the non-light-transmitting part by being closely adhered to the non-light-transmitting part as a secondary molded part.
2. Two-color molding according to claim 1,
a part of the non-light-transmitting portion surrounding the light-transmitting portion is notched, an outward protruding portion of the light-transmitting portion is engaged with the notched portion and is in close contact therewith, and a gate mark for injection molding is provided on an end surface of the outward protruding portion exposed to be flush with an outer peripheral surface of a side edge portion of the two-color molded product.
3. Two-color shaped member according to claim 1 or 2,
linear ribs extending in the circumferential direction are continuously or discontinuously provided on the inner sides of the leg portions provided on the outer and inner peripheral edge portions of the non-light-transmitting portion.
4. The two-color molding according to claim 3,
the leg portion is provided with a plurality of parallel linear ribs.
5. The two-color molding according to claim 3,
the maximum projection amount of the linear rib is within 0.5 mm.
6. The two-color molding according to claim 3,
the linear rib is provided in the light transmission portion having a fall angle of 45 degrees or more.
7. Two-color molding according to claim 1,
the fine unevenness is provided over the entire surface of the surface.
8. Two-color molding according to claim 1 or 7,
the fine unevenness is also provided on the back surface of the light-transmitting portion.
9. A two-color molding method is a method for molding a two-color molded article, and the two-color molded article comprises: a light-transmitting portion formed of a light-transmitting resin member, the surface of which is provided with fine irregularities by injection molding; and a non-light-transmitting portion which is formed of a colored member and extends so as to surround the outer periphery of the light-transmitting portion without being laminated with the light-transmitting portion in the plate thickness direction,
the two-color molding method comprises:
a primary molding step of molding the frame-shaped non-light-transmitting portion by closing a fixed-side mold and a primary movable-side mold and injecting a colored resin member into a first molding space defined by the fixed-side mold and the primary movable-side mold; and
and a secondary molding step of integrally molding the light-transmitting portion inside the non-light-transmitting portion by clamping the fixed-side mold and the secondary movable-side mold while maintaining the non-light-transmitting portion, and injecting a light-transmitting resin member into a second molding space defined by the clamping.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2019-226228 | 2019-12-16 | ||
| JP2019226228A JP7454939B2 (en) | 2019-12-16 | 2019-12-16 | Two-color molded product and two-color molding method |
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| CN112984459A true CN112984459A (en) | 2021-06-18 |
| CN112984459B CN112984459B (en) | 2024-02-13 |
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| CN202011486464.XA Active CN112984459B (en) | 2019-12-16 | 2020-12-16 | Bicolor molding part and bicolor molding method |
| CN202023031708.3U Active CN214275578U (en) | 2019-12-16 | 2020-12-16 | Two-color molded part |
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| JP7454939B2 (en) * | 2019-12-16 | 2024-03-25 | 株式会社小糸製作所 | Two-color molded product and two-color molding method |
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| JP2015205494A (en) | 2014-04-23 | 2015-11-19 | 株式会社小糸製作所 | Two-color molding method, metal die for two-color molding, and two-color molded article |
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| CN101376262A (en) * | 2007-08-30 | 2009-03-04 | 深圳富泰宏精密工业有限公司 | Shaped part and dual-color molding method for producing the shaped part |
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Also Published As
| Publication number | Publication date |
|---|---|
| JP7454939B2 (en) | 2024-03-25 |
| CN214275578U (en) | 2021-09-24 |
| CN112984459B (en) | 2024-02-13 |
| JP2021094729A (en) | 2021-06-24 |
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