GB2424613A - Method for manufacturing moulded article with insert located theirin - Google Patents
Method for manufacturing moulded article with insert located theirin Download PDFInfo
- Publication number
- GB2424613A GB2424613A GB0606569A GB0606569A GB2424613A GB 2424613 A GB2424613 A GB 2424613A GB 0606569 A GB0606569 A GB 0606569A GB 0606569 A GB0606569 A GB 0606569A GB 2424613 A GB2424613 A GB 2424613A
- Authority
- GB
- United Kingdom
- Prior art keywords
- resin
- molded article
- cavity
- primary
- wall portion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 23
- 229920005989 resin Polymers 0.000 claims abstract description 46
- 239000011347 resin Substances 0.000 claims abstract description 46
- 238000002844 melting Methods 0.000 claims abstract description 19
- 230000008018 melting Effects 0.000 claims abstract description 19
- 238000002347 injection Methods 0.000 claims description 9
- 239000007924 injection Substances 0.000 claims description 9
- 238000005304 joining Methods 0.000 claims description 3
- 229920005992 thermoplastic resin Polymers 0.000 description 9
- 238000001746 injection moulding Methods 0.000 description 6
- 229920001169 thermoplastic Polymers 0.000 description 6
- 239000004416 thermosoftening plastic Substances 0.000 description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- 229910052710 silicon Inorganic materials 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- 230000002093 peripheral effect Effects 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 230000000712 assembly Effects 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 230000001133 acceleration Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
Classifications
-
- 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
- B29C45/0046—Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
-
- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14065—Positioning or centering articles in the mould
-
- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14819—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being completely encapsulated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/023—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for transmission of signals between vehicle parts or subsystems
- B60R16/0239—Electronic boxes
-
- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14639—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles for obtaining an insulating effect, e.g. for electrical components
-
- 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
- B29C45/1671—Making multilayered or multicoloured articles with an insert
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
A method for manufacturing a resin moulded article comprises locating an insert 3 into a mould cavity W such that at least two parts of the insert 3 abut on a wall portion 4a,b,c,d,e, 5a,b,c,d of the mould M, so that the insert is seized to the wall portion. A melting resin is injected into the cavity through a predetermined position 11 of the mould to form the resin moulded article in the cavity. The predetermined position is determined such that the filling pressure of the melting resin injected into the cavity presses the at least two parts of the insert onto the wall portion, to hold the insert on said wall portion. Later embodiments relate to a method of manufacturing a regulator case 1 and a regulator case manufactured according to the said method.
Description
METHOD FOR MANUFACTURING
MOLDED ARTICLE WITH INSERT LOCAThD THEREIN
FIELD OF THE INVENTION
The present invention relates to methods for manufacturing molded articles with an inset located therein by means of injection molding. More particiSarly, the present invention relates to molded articles, such as regulator cases for regulators, which are manufactured using the methods set forth above.
BACKGROUND OF E INVENTION
In conventional methods for manufacturing a resin-molded article with an insert embedded therein, at least one of a stationary mold member and a movable mold member of a mold for injection molding is equipped with a sleeve retainer pin for holding the insert in the cavity between opposing inner wail surfaces of the respective stationary and movable mold members. An example of the conventional methods for manufacturing a resin-molded article with an insert embedded therein using such a sleeve retainer pin is disclosed in Japai*se unexamined utility model publication No. H05068621.
According to this utility model publication, an insert is located in a cavity between an inner wail surface of the stationary mold member arid that of the movable mold member. A sleeve retainer pin is located in the catty and arranged to press at its tip end the insert to abut it on the inner wall surface of the stationary mold member, thereby fixedly holding the insert in the catty. Thereafter, a thermoplastic resin is injected into the catty, and thereafter, the sleeve retainer pin is moved so that the tip end thereof is aligned with the inner wail surface of the movable mold member. After the positioning of the sleeve retainer pin, a thermoplastic resin is inserted into the space where the sleeve retainer pin had been occupied, resulting that a resin-molded article with the insert embedded therein is manufactured.
In the manufacturing method disclosed in the utility model publication, part of the molded portion that is contacted to the outer peripheral surface of the sleeve retainer pin is hardened more quickly than another part of the molded portion. This may create two or more melt fronts, which represent the locations of the leading edges of flows of the injected resin in the cavity, causing weld lines (Imit lines) to appear at the locations in the part of the molded portion where the two or more melt fronts meet These weld lines deteriorate the resin-molded article manufactured by the conventional manufacturing method using such a sleeve retainer pin.
In order to avoid the occurrence of the weld lines, when the movement of the sleeve retainer pin up to the inner wail surface of the movable mold member is accelerated, the pressure of the injected ret into the cavity may press the insert so that the insert may be widely shifted from its designed position. This may expose part of the insert outside of the molded article.
If the molded article with part of the insert being externally exposed is installed in a vehicle, water may enter into the molded article through a portion between the molded resin part and the exposed part. If the molded article includes terminals, this entry of the water into the molded article may cause electrical leaks between the terminals and/or corrosion of each terminal.
SUMMARY OF THE INVENTION
In view of the background, an object of at least one preferable embodiment of the present invention is to securely position an insert in a cavity of a mold without using retainer pins, allowing manufacturing of a good resin-molded article in which an. insert is located.
According to a first aspect of the present invention, there is provided a method for manufacturing a resin-molded article using an insert and a mold having a wall portion defining a cavity therein. The cavity has a predetermined configuration defined by a size and structure of the resinmolded article. The method includes locating the insert in the cavity to abut at least two parts of the insert on the wall portion so that the insert is seized to the wail portion. The method also includes injecting a melting resin into the cavity through a predetermined position of the mold to be filled therein to form the resin-molded article in the cavity. The predetermined position is determined such that filling pressure of the melting resin injected into the cavity presses the at least two parts of the insert onto the wall portion to hold abutment state of the at least two parts of the insert on the wall portion.
According to a second aspect of the present invention, there is provided a method for manufacturing a regulator case as a secondary resin-molded article using a primary resin-molded article with terminals and a mold having a wall, portion defining a cavity therein. The cavity has a predetermined configuration defined by a size and sfr'ucture of the regulator case. The method includes locating the primary resin-molded article as an insert in the cavity to abut at least two parts of the primary resin-molded article on the wall portion so that the primary resin-molded 3.
article is seized to the wall portion, The method also includes injecting a melting resin into the cavity through a predetermined position of the mold to be filled therein to form the regulator case in the cavity. The predetermined position is determined such that filling pressure of the melting resin injected into the cavity presses the at least two parts of the primary resin-molded article onto the wall portion to hold abutment state of the at least two parts of the primary resin-molded article on the wall portion, According to a third aspect of the present invention, there is provided a method for manufacturing a regulator case as a secondary resin-molded article using a primary resin-molded article with terminals and a mold having a wall portion defining a cavity therein. The pthnaxy resin-molded article includes a connector portion for supporting the terminals, and an extending portion extending from the connector portion and having connector elements electrically connected to the terminals.
The regulator case includes a first housing integrally enclosing the connector portion, a second housing integrally surrounding part of the extending portion, and a third housing integrally joining to the remaining part of the extending portion and having a container therein. The cavity has a predetermined configuration defined by a size and structure of the regulator case. The method includes locating the primary resin-molded article as an insert in the cavity to abut at least two parts of the primary resin-molded article on the wall portion so that the primary resin-molded artiéle is seized to the wall portion. The method also includes injecting a melting resin into the cavity through a predetermined position of the mold to be filled therein to form the regulator case in the cavity. The predetermined position is deterxnined such that filling pressure of the 4.
melting resin injected into the cavity presses the at least two parts of the primary resin-molded article onto the wall portion to hold abutment state of the at least two parts of the primary resin-molded article on the wall portion.
According to a fourth aspect of the present invention, there is provided a resin-molded article manufactured by the method of the first aspect of the present invention.
According to a filth aspect of the present invention, there is provided a regulator case manufactured by the method of the second aspect of the present invention.
According to a sixth embodiment of the present invention, there is provided a regulator case manufactured by the method of the third aspect of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and aspects of the invention will become apparent from the following description of embodiments with reference to the accompanying drawings in which: Fig. 1 is an exploded perspective view schematically illustrating a regulator assembly for alternators according to a first embodiment of the present invention; Fig. 2 is a perspective view schematically illustrating a regulator case illustrated in Fig. 1 in which a primary resin-molded article is located according to the first embodiment; Fig. 3 is a perspective view schematically illustrating the primary resin-molded article illustrated in Fig. 2 according to the first embodiment; 5.
Fig. 4A is a cross-sectional view taken on lines WA-WA of Fig. 43, illustrating a mold having a cavity in which a primary resin-molded article is located according to the first embodiment; Fig. 43 is a crosssectional view taken on lines NB-P/B of Fig. 4A; Fig. 5 is a crosssectional view corresponding to Fig. 4A, illustrating a mold having a cavity in which a primary resin-molded article is located according to a second embodiment of the present invention; Fig. 6 is a cross-sectional view corresponding to Fig. 4A, illustrating a mold having a cavity in which a primary resin-molded article is located according to a third embodiment of the present invention; Fig. 7 is a cross-sectional view corresponding to Hg. 4A, illustrating a mold having a catty in which a primary resin-molded article is located according to a fourth embodiment of the present invention; and Fig. 8 is a cross-sectional view corresponding to Fig. 4A, illustrating a mold having a cavity in which a primary resin-molded article is located according to a fifth embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
Embodiments of the present invention will be described hereinafter with reference to the accompanying drawings.
In each of the embodiments, the present invention is applied to methods for manufacturing a regulator case for regulators as an example of resinmolded articles. In the drawings in the embodiments, like reference characters arc assigned to like elements.
First embodiment A first embodiment of the present invention will be described hereinafter, Referring to Figs. 1 to 4, there is illustrated a regulator case 1 for regulators of alternators for example. The regulator case 1 is a secondary thermoplastic resin-molded article that has been manufactured by: preparing a mold M composed of a pair of stationary and movable mold members 4 and 5 defining a cavity W therebetween that has a predetennined configuration determined by the size and structure of the secondary thermoplastic resin-molded article (regulator case) 1; locating a primary resin-molded article with terminals provided therein, which has been manufactured by means of, for example, insert molding, in the cavity W at a predetermined position thereof; and injecting a thermoplastic resin into the cavity W to form the secondary thermoplastic resin-molded article (regulator case 1) integrated with the primary resin-molded article.
The regulator case 1 is configured to hold a substantially plate-like regulator circuit board 6, such as a hybrid IC board, and electrical elements; the regulator case 1 in which these regulator circuit board 5 and the electrical component are held serves as a regulator assembly RA.
Specifically, the regulator assembly RA is designed to be mountable on/to an alternator instailable in a vehicle and having a poled rotor and a stator in which three-phase windings are provided.
When the regulator assembly RA is mounted to the alternator installed in the vehicle, the regulator assembly RA is operative to regulate electric power to be fed to the poled rotor that is rotating based on torque supplied from sri engine of the vehicle. The alternator is operative to output a three-phase AC (alternating current) voltage based on magnetic fluxes formed across the three-phase windings, Specifically, the 7.
regulation of the electric power to be supplied to the poled rotor by the regulator assembly allows the generated DC voltage output from the alternator to be stable. The DC voltage output from the alternator is fed to a battery installed in the vehIcle and/or to electrical components installed therein.
The regulator case 1 has predetermined size and structure disclosed in Figs. 1. and 2. Specifically, the regulator case 1 is composed of a terminal holder 3 as the primary resin-molded article (see Fig. 3).
The terminal holder 3 is made up of a substantially rectangularcylindrical connector portion 7 with rounded corners. The connector portion 7 has axially opposing first and second end surfaces 7a and 7b. The connector portion 7 includes connector terminals 2 one ends of which are embedded in the connector portion 7 from the first end surface 7a thereof such that the connecter terminals 2 are arranged to be parallel to the axial direction of the connector portion 7. The connector tenninais 2 are formed by means of, for example, insert molding.
The terminal holder 3 is also made up of a plate-like extending portion 9 integrally extending obliquely from the bottom side end of one side surface of the connector portion 7 in orthogonal to the axial direction of the connector portion 7.
The terminal holder 3 is further made up of a substantially rectangularcylindrical stiffening rib 10 integrally joining at its first side surface to a first longitudinal side surface (inner side surface) 9a of the extending portion 9 and at its second longitudinal side surface adjacent to the first side surface to the one side surface of the connector portion 7.
The extending portion 9 is also provided with a terminal support bar 8 integrally mounted at its first longitudinal side surface on a second longitudinal side surface 9b of the other end of the extending portion 9, which is parallel to the first end surface 7a of the connector portion 7.
The terminal support bar is formed with connector elements Ba paraliely projecting away from its second longitudinal side surface opposite to the first longitudinal side surface in orthogonal to the axial direction of the connector portion 7 and the extending direction of the extending portion 9. The terminal elements Ba are electrically connected respectively to the connector terminals 2 through, for example, the terminal holder 3. The terminal elements Ba are formed by means of, for example, insert molding.
In addition, the regulator case 1 is composed of a substantially rectangular annular housing (first housing) 21, an extending housing (a second housing) 22, and a substantially rectangular annular housing (third housing) 23, which corresponds to the secondary resin-molded article. That is, the first to third housings 21 to 23 are integrally molded with the terminal holder 3.
Specifically, the first housing 21 has rounded corners and axially first and second open end surfaces. The first housing 21 is formed at its part of the second open end surface side of one side surface with a channel. The first housing 21 is combined with the connector portion 7 and the extending portion 9 such that the peripheral side portion and the second end surface of the connector portion 7 are integrally fitted in the second open end surface and the inner peripheral side portion of the first housing 21, respectively. In addition, the extending portion 9 is integrally fitted in the channel. The first housing 21 also has a bracket 21a with a mounting hole 21 al. The second housing 22 has a substantially rectangular annular 9.
shape and integrally extends from the first housing 21 such that the inner peripheral portion of the second housing 22 integrally surrounds the extending portion 9 arid the stiffening rib 10 integrated therewith. The second housing 22 has a bracket 22a with a mounting hole 22a1.
The third housing 23 has substantially rectangular first and second open end portions and a compartment R formed thereinside in which the regulator circuit board 6 is housed.
The third housing 23 integrally extends from the second housing 22 such that part of the inner periphery of the first open end portion of the third housing 23 is integrally joined to corresponding part of a third longitudinal side surface Sb of the terminal support bar 8 adjacent to a third longitudinal side surface of the extending portion 9 opposite to the first longitudinal side surface 9a. The third housing 23 has a pair of brackets 23a and 23b respectively with mounting holes 23a1 and 23b1.
Moreover, as illustrated in Fig. 1, the regulator assembly RA is provided with a substantially rectangular silicon gel member S enclosed within the container R so as to watertightly abut on one planer surface 6a of the regulator circuit board 6 housed in the container R. The regulator assembly RA is also provided with a lid plate 12 with which the second opening end portion of the third housing 23 is covered.
In addition, the regulator assembly RA is provided with a finned heatsink 13 with which the first opening end portion of the third housing 23 is covered. The finned heat sink 13 is, for example, mounted on the other planer surface Sb opposing to the one planer surface 6a of the regulator circuit board 6 and configured to dispose of unwanted heat in the regulator circuit board 6.
The above structured regulator assembly RA is attached to the alternator installed in the vehicle by means of the mounting holes 2 lal, 22a1, 23a1, and 23b1 using, for example, screws. At least one of the attachment structures, for example, can establish electrical links between terminals of the alternator and the terminals of the regulator circuit board 6.
When manufacturing the regulator case 1 with the above configuration as a secondary molded article set forth above, an injection-molding machine liv! equipped with the paired stationary and movable mold members 4 and 5 of the mold M is prepared.
As illustrated in Figs. 4A and 43, the stationary mold member 4is composed of a first stationary mold member 4A and a second stationary mold member 43. The second stationary mold member 48 has a substantially rectanguiar-paralielepiped such that the first stationary mold member 4A surrounds the second stationary mold member 43 with is a substantially predetermined space therebetween. The second stationary mold member 43 corresponds to the compartment R of the third housing 23.
The stationary mold members 4A and 4B include wall portions opposing to each other, and the movable mold member 5 includes a wall portion opposing to the wail portion of each of the first and second stationary mold members 4A and 43. These opposing wall portions of the mold members 4A, 43, and $ define a cavity W having a predetermined configuration defined by the size and structure of the regulator case 1.
The wail portion of the second stationary mold member 48 includes a pair of opposing first and second wall surfaces 4b and 4e and a pair of opposing third and fourth wail surfaces 4c and 4d. *11
The injection-molding machine IM is also composed of an injection unit with a nozzle, a runner communicated therewith and a gate 11. The gate 11 is formed in the first stationary mold member 4A at a predetermined position thereof described hereinafter as to be communicated with the runner. The gate 11 consists of an opening allowing a thermoplastic resin injected from the injection unit through its nozzle and the runner to enter into the cavity W therethrough.
Next, the primary resin-molded article (terminal holder) 3 is located as an insert in the cavity W such that a plurality of parts of the primary resin-molded article 3 abuts on at least one of the wall portions of the stationary and movable mold members 4 and 5, which seizes the primary resin-molded article 3 to the mold M to locate it in the cavity W. Specifically, as illusfratecl in Fig. 4A, a fourth longitudinal side surface 8c (abutment portion P1) opposing to the third longitudinal side surface Sb of the terminal support bar 8 (see Fig. 3) of the primary resin-molded article 3 abuts on the first wall surface 4b of the second stationary mold member 43 and an opposing part Sa of the wall portion of the movable mold member 5. PartIcularly, the end surface of the tip end portion 8d of the terminal support bar S is aligned with the fourth wall surface 4d of the second stationary mold member 43.
In addition, a third side surface lOa (abutment portion P2) of the stiffening rib 10 opposing to the second side surface of the stiffening rib of the primary resin-molded article 3 abuts on the third wall surface 4c of the second stationary mold member 43. Moreover, the first end surface 7a of the connector portion 7 of the primary resin-molded article 3 abuts on an opposing part of the wall portion of the movable mold member 5.
These abutments between parts of the primary resin-molded article (terrriinal holder) 3 and opposing those of the mold M allow the primary resin-molded article 3 to be seized to the mold M, thereby positioning the primary resin-molded article 3 in the cavity W. The gate 11 is disposed to a portion 4a of the first stationary mold member 4A that faces the third longitudinal side surface opposing to the first longitudinal side surface 9a of the extending portion 9 of the primary resin-molded article 3. In other words, the gate is disposed to the portion 4a of the first stationary mold member 4A that faees the second stationary mold member 45 through the extending portion 9 of the primary resin-molded article 3.
After location of the primary resin-molded article 3 in the cavity W, as illustrated by arrows A in Fig. 4A, a thermoplastic resin is injected from the irjecfion unit through its nozzle, so that the injected resin flows through the runner, and enters into the cavity W through the gate 11 to be filled therein. The filling pressure of the resin into the cavity W acts on the primary resin-molded article 3.
Specifically, a first filling pressure of the resin acting on the third longitudinal side surface Sb of the terminal support bar 8o1 the extending portion 9 presses it toward the opposing parts 4b and 5a of the wall portions of the respective stationary and movable mold members 45 and 5 (see an arrow B in Fig. 4A). Simultaneously, a second filling pressure of the resin acting on the parts 4e and 5b of the wall portions of the respective stationary and movable mold members 45 and 5 facing the parts 4b and 5a thereof also presses them toward the parts 4b and 5a (see an arrow E in Fig. 4A).
The first and second filling pressures are substantially balanced to each other. Thus, these first and second filing pressures allow the extending portion 9 of the prixnaiy resin-molded article 3 to be fixedly crimped onto the wail portions of the respective stationary and movable mold members 43 and 5.
Similarly, a third filling pressure of the resin acting on the third side surface lOa (abutment portion P2) of the primary resin-molded article 3 presses it toward the opposing parts 4c and 5c of the wall portions of the mold member 43 and 5 (see an arrow C in Fig. 4A). Simultaneously, a fourth filling pressure of the resin acting on tip end portion 3d of the tenyjinal support bar S of the extending portion 9 also presses it toward theparts4caz1d5cofthewallpo ons(seeanazmwDinpg. 4A). The third and fourth filling pressures are substantially balanced to each other.
Thus, these third and fourth filling pressures allow the third side surface P2 of the primary resin-molded article 3 to be fixedly crimped onto the wall portion of the second stationary mold member 4B.
In addition, a fifth filling pressure of the resin acting on a part of the wall portion of the stationary mold member 4 facing the first end sw- face 7a of the connector portion 7 of the primary resin-molded article 3 presses it toward the first end surface side (see an arrow F in Fig. 4A).
This allows the first end surface 7a of the connector portion 7 of the primary resin-molded article 3 to be fixedly crimped onto the wall portion of the movable mold member 5.
In other words, the gate 11 is disposed to a predetermined position of the mold M such that the filling pressure of the resin being injected into the cavi W allows abutment state of the primary resin-molded article 3 on the mold M to be held.
As described above, when the thermoplastic resin is injected into *14- the cavity W, the primary resin-molded article 3 is pressed to fixedly abut on the stationary and movable mold members 4 and 5 in the catty W by the filing pressure of the resin entering thereinto. This allows the secondaiy thermoplastic resin-molded article 1 to be smoothly formed in the cavity W. After the injection molding, the mold M in which the secondary thermoplastic resin-molded article us formed is cooled. Thereafter, the movable mold member 5 is removed from the stationary mold member 4, and thereafter, the secondary thermoplastic resin-molded article (regulator case 1) is removed from the cavity W, so that nianufacturing of the regulator case 1 has been completed.
After completion of manufacturing of the regulator case 1, the silicon gel member S is enclosed in the third housing 23 of the regulator case 1 to abut on the abutment portions P1 and P2 of the terminal support barS and the stiffening rib 10 of the primary resin-molded article 3; these abutment portions P1 and P2 had contacted to the wall portions 4b, 4c, and Sa of the mold M. even if part of the primary resin-molded article 3 is exposed at the abutment portions P1 and P2, the silicon gel member S enclosed in the third housing 23 therefore can render the exposed part of the primary resin-molded article 3 waterproof. This allows no water exposure routes to be formed at the abutment portions P1 and P2. As a. result, it is possible to prevent electrical leakage between the electrical elements (e.g. terminals 2) partially embedded in the primary resin-molded article 3 and corrosion of the electrical terminals (e.g. the terminals 2), This allows the normal functions of the regulator assembly PA to be maintained over a long period of time. -
As set forth above, the manufacturing method according to the first embodiment effectively uses the filling pressure of the resin being injected into the cavity W to seize the primaiy resin-molded article 3 in the cavity W without using retainer elements, such as retainer pins, thereby manufacturing the secondary resin-molded article (regulator case) 1. No use of retainer elements allows the cost of manufacturing the regulator cases 1 and regulator assemblies RM to decrease. In addition, no use of retainer elements permits the molding works of the regulator cases 1 to be accelerated, maldng it possible to realize grate productivity of regulator cases 1 and regulator assemblies RM using them.
Second embodiment Fig. 5 schematicafly illustrates a mold M having a cavity W in which a primary resin-molded article 3A is located according to a second embodiment of the present invention.
In the second embodiment, a terminal support bar 8W of the extending portion 9 is formed at its tip end portion 3d with chamfered corner 8e. The chamfered corner Be has an inclined surface such that the lateral width of the terminal support bar SW is tapered from the gate side end thereof toward the fourth wall surface 4d of the wall portion of the second stationary mold member 43. This allows the resin being injected from the gate 11 to smoothly flow around the tapered inclined corner portion Be through the cavity W. This can prevent stagnation flow of the injected resin around the tip end portion 3d of the terminal suppoi-t bar 8 of the extending portion 9, making it possible to improve the flowability of the resin being injected into the cavity W. This can contribute to acceleration of the molding works of the regulator cases I. and to improvement of accuracy of the secondary resin-molded articles 1.
Note that, in the second embodiment, illustration of the mold M corresponding to Fig. 43 is omitted, because the structure of the mold M according to the second eml$odiment is substantially identical with that of the mold M according to the first embodiment. This omission will be applied to the other embodiments described hereinafter.
Third embodiment Fig. 5 schematically illustrates a mold M having a cavity W in which a primary resin-molded article is located according to a third embodiment of the present invention. In the third embodiment, a terminal support bar 8X of the extending
portion 9 is formed at its tip end portion Sd with a flange Sf (abutment portion P3), The flange SI projects from the tip end portion 8d by a predetermined length such that the flange Sc! of the terminal support bar 8X abuts on opposing parts 4d and 5d of the wall portions of the stationary and movable mold members 43 and 5. This configuration allows a filling pressure of the resin acting on the flange Sf of the terminal support bar SX of the extending portion 9 to press it toward the parts 4c and Sc of the wall portions.
Specifically, in the third embodiment, the extending portion BY of the primary resin-molded article 3 abuts on the stationary and movable mold members 4 and 5 at three abutment portions P1. to Pa. This makes it possible to more stably hold the primary resin-molded article 3 in the cavity W, which can contribute to improvement of accuracy of the secondary resin-molded articles 1. - 17-
Fourth embodiment Fig. 7 scheinaticafly illustrates a mold M having a cavity W in which a primary resin-molded article is located according to a fourth embodiment of the present invention.
In the fourth embodiment, the gate 1 1A is disposed to a portion 4f of the first stationary mold member 4A that faces the fourth wall surface 4d of the second stationary mold member 4B, In addition, each of the third longitudinal side surface Sb of a terminal support bar BY and the longitudinal side surface of the extending portion 9 are integrally formed with a taper portion T. The taper portion F is configured such that the lateral width of each of the terminal support bar BY and the other end of extending portion 9 is tapered from the connector portion side toward the gate 1 1A. Moreover, like the third embodiment, the terminal support bar BY is formed at its tip end portion Sd with the flange Sf.
According to the fourth embodiment, a thermoplastic resin is injected from the injection unit through its nozzle, so that the injected resin flows through the runner, and enters into the cavity W through the gate 1 LA (see an arrow A in Fig. 7). When the resin entered into the cavity W from the gate 1 1A flows through the taper portion T, vertical component 0 acting on the terminal support bar BY presses it toward the opposing parts 4b and 5a of the wall portions of the respective stationaty and movable mold members 4B and 5.
The vertical component 1) in addition to the filling pressure of the resin allows the extending portion 9 of the primary resin-molded article 3 to be more fixedly crimped onto the wall portions of the respective stationaxy and movable mold members 4B and 5. This makes it possible is.
to more stably hold the primary resin-molded article 3 in the cavity W, which can further contribute to improvement of accuracy of the secondary resin-molded articles 1.
The arrangement of the gate 1 1A at the portion 4f of the first stationary mold member 4A that faces the fourth wall surface 4d of the second stationary mold member 4B is preferable in, for example, a following case. Specifically, there is a case where it is difficult to dispose the gate to the portion 4a of the first stationary mold member 4A that faces the third longitudinal side surface of the extending portion 9 due to the limitation of the setting of the mold M, so that filling of the resin into the cavity W is insufficient to abut the primary resin- molded article 3 on the mold M. Fifth embodiment Fig. 8 schematically illustrates a mold M having a cavity W in which a primary resin-molded article is located according to a fifth embodiment of the present invention.
In the fifth embodiment, the gate 113 is disposed to a portion 4g of the first stationary mold member 4A that faces the connector portion side of the extending portion 9.
In addition, each of the third longitudinal side surface 8b of a terminal support bar 8Z and the longitudinal side surface of the extending portion 9 are integrally formed with a taper portion Ti. The taper portion Ti is configured such that the lateral width of each of the terminal support bar SZ and the other end of extending portion 9 is tapered from the tip end portion Sd toward the gate 1 lB.
Moreover, a stiffening rib iOA is provided at its third side surface side end with a flange lOb projecting therefrom by a predeterrnfried length such that the flange 1 Ob abuts on the wall surface 4c of the wall portion of the second stationary mold member 4B.
According to the fifth embodiment, a thermoplastic resin is injected from the injection unit through its nole, so that the injected resin flows through the runner, and enters into the cavity W through the gate 118 (see an arrow B in Fig. 8). When the resin entered into the cavity W from the gate 113 flows through the taper portion Ti (see an arrow H in Fig. 8) , vertical component I acting on the terminal support bar SZ presses it toward the opposing parts 4b and 5a of the wall portions of the respective stationary and movable mold members 43 and 5.
The vertical component i in addition to the filling pressure of the resin allows the extending portion 9 of the primary resin-molded article 3 to be more fixedly crimped onto the wall portions of the respective stationary and movable mold members 43 and 5. This makes it possible to more stably hold the primary resin-molded article 3 in the cavity W, which can ftn-ther contribute to improvement of accuracy of the secondary resin-molded articles 1.
in the structhre of the fifth embodiment, the connector portion 7 presses the stiffening rib iOA onto the second mold member 43 during injection of the resin into the cavity W through the gate 1 iS. The flange portion 1 Ob of the stiffening rib 1 OA can counterwork against the pressing force from the connector portion 7.
The positions of the gate and the taper portion, and the taper degree of the taper portion would be determined accordingly to create pressing force allowing the primary resin-molded article 3 to abut on the mold M. 20* In each of the first to fifth embodiments, the terminal holder 3 is applied to a primary resin-molded article, and the regulator case 1 for regWators is applied to a secondary resin-molded article, but the present invention is not limited to these applications. Specifically, various types of elements can be applied to a primary resin-molded article and/or a seconclasy resin-molded article.
In each of the first to fifth embodiments, the silicon gel member S is used to be enclosed in the container It so as to watertightly abut on the regulator circuit board 6, but other types of waterproofing members, such as a member iii which liquid material (e.g. epoxy resin) is tightly filled, can be used in place of the silicon gel member S. As long as the fi]iing pressure of the resin being injected into the cavity W allows abutment state of the primary resin-molded article 3 on the mold M to be held, the primary resin-molded article 3 can abut on the mold M at least two parts thereof. Specifically, the number of parts of the primary resinmolded article 3 abutting on the mold M depends on the configuration of the primary resin-molded article 3.
As a thermoplastic resin used for injection molding to manufacture a secondary resin-molded article 1, various types of melting resins can be used.
As set forth above, in each of the first to fifth embodiments and their modifications, it is possible to stably seize a primary resin-molded article in a cavity without using retainer elements, thereby manufactu4ig a secondary resin-molded article. In addition, even if a primary resinmolded article is an electrical component with electrical elements (e.g. terminals), it is possible to prevent electrical leakage between the electrical elements and corrosion of the electrical elements. This makes it possible to improve the quality arid durability of secondaxy resin-molded articles.
While there has been described what is at present considered to be the embodiments arid their modificaflons of the present invention, it will be understood that various modifications which are not described yet may be made therein, and it is intended to cover in the appended claims all such modificions as fall within the true spirit and scope of the invention.
Claims (12)
1. A method for manufacturing a resin-molded article using an insert and a mold having a wail portion defining a cavity therein, the cavity having a predetermined configuration defined by a size and structure of the resin-molded article, the method comprising: locating the insert in the cavity to abut at least two parts of the insert on the wall portion so that the insert is seized to the wail portion; and thjecting a melting resin into the cavity through a predetermined position of the mold to be filled therein to form the resin-molded article in the cavity, the predetennined position being determined such that filling pressure of the melting resin injected into the cavity presses the at least two parts of the insert onto the wall portion to hold abutment state of the at least two parts of the insert on the wall portion.
2. A method for manufacturing a regulator case as a secondary resinmolded article using a primary ret-molded article with terminals and a mold having a wall portion defining a cavity therein, the cavity having a predetermined configuration defined by a size and structure of the regulator case, the method comprising: locating the primary resin-molded article as an insert in the cavity to abut at least two parts of the primary resin-molded article on the wall portion so that the primary resin-molded article is seized to the wall portion; and injecting a melting resin into the cavity through a predetermined position of the mold to be filled therein to form the regulator case in the cavity, the predetermined position being determined such that filling pressure of the melting resin injected into the cavity presses the at least two parts of the pthnazy resin-molded article onto the wail portion to hold abuthient state of the at least two parts of the primary resin-molded S article on the wall portion.
3. A method for manufacturing a regulator case as a secondary resinmolded article using a primary resin-molded article with termJna and a mold having a wall portion defining a cavity therein, the primary resinmolded article including a connector portion for supporting the terminals, and an extending portion extending from the connector portion and having connector elements electrically connected to the terminals, the regulator case including a first housing integrally enclosing the connector portion, a second housing integrally surrounding part of the extending portion, and a third housing integrally joining to the remaining part of the extending portion and having a container therein, the cavity having a predetermined configuration defined by a size arid structure of the regulator case, the method comprising: locating the primary resin-molded article as an insert in the cavity to abut at least two parts of the primary resin-molded article on the wall portion so that the primary resin-molded article is seized to the wall portion; and injecting a melting resin into the cavity through a predetermined position of the mold to be filled therein to form the regulator case in the cavity, the predetermined position being determined such that filling pressure of the melting resin injected into the cavity presses the at least two parts of the primary resin-molded article onto the wall portion to hold abutment state of the at least two parts of the primary resin-molded article on the wall portion.
4. A method according to any one of claims 2 and 3, characterized in that the locating locates the primary ret-molded article in the cavity to abut the primary resin-molded article on three or more parts of the wall portion so that the primary resin-molded article is seized to the wall portion.
5. A method according to claim 1, further comprising removing the resinmolded article from the cavity of the mold; and enclosing the at least two parts of the insert of the resin-molded article with an watertight member.
6. A method according to claim 2 or claim 3, further comprising: removing the regulator case from the cavity of the mold; and inserting an watertight member in the regulator case to enclose the at least two parts of the primary resin-molded article.
7. A method according to claim 3, characterized in that the extending portion of the primary resin-molded article has a taper portion, any one of the at least two parts of the primary resin-molded article facing the taper portion.
8. A method according to claim 7, characterized in that the predetermined position of the melting resin injection and the taper portion are substantiaUy opposite to each other such that a lateral width of the extending portion is tapered toward the predetermined position of the melting resin injection.
9. A method according to claim 7, characterized in that the predetermined position of the melting resin injection and the taper portion are substantially opposite to each other such that a lateral width of the extending portion is tapered away from the predetermined position of the melting resin injection.
10. A resin-molded article manufactured by the method according to claim 1.
11. A reguiator case manufactured by the method according to claim 2.
12. A regulator case manufactured by the method according to claim 3, "26'
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2005104889A JP2006281622A (en) | 2005-03-31 | 2005-03-31 | Double resin injection molding method, resin product molded by the method, and regulator case for alternator |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB0606569D0 GB0606569D0 (en) | 2006-05-10 |
| GB2424613A true GB2424613A (en) | 2006-10-04 |
| GB2424613B GB2424613B (en) | 2010-07-28 |
Family
ID=36425053
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0606569A Expired - Fee Related GB2424613B (en) | 2005-03-31 | 2006-03-31 | Method For Manufacturing Molded Article With Insert Located Therein |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP2006281622A (en) |
| GB (1) | GB2424613B (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1810810A1 (en) * | 2006-01-18 | 2007-07-25 | Sumitomo Wiring Systems, Ltd. | Moulding construction and a molding method of a resin-molded product |
| US7776247B2 (en) | 2007-06-04 | 2010-08-17 | Denso Corporation | Method of manufacturing electronic device having resin-molded case and molding tool for forming resin-molded case |
| WO2013144008A1 (en) * | 2012-03-27 | 2013-10-03 | Louise Mohn | Moulding method |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2446865A1 (en) | 2010-10-28 | 2012-05-02 | Louise Mohn | Thermostimulation apparatus |
| JP2016137639A (en) * | 2015-01-28 | 2016-08-04 | 矢崎総業株式会社 | Method for manufacturing electric box made of resin |
| CN114536646B (en) * | 2021-10-29 | 2023-11-17 | 浙江新大塑料管件有限公司 | Wire winding and demolding integrated machine for electric smelting pipe fitting |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH06111653A (en) * | 1991-09-28 | 1994-04-22 | Omron Corp | Method for forming insertion part of terminal fitting of electric equipment |
| JPH0780890A (en) * | 1993-09-13 | 1995-03-28 | Ueda Kanagata:Kk | Molding method for synthetic resin product with insert embedded and synthetic resin biological model with insert wire embedded |
| EP1097740A1 (en) * | 1999-05-10 | 2001-05-09 | Takara Co., Ltd. | Arm part for elastic doll body, method of forming the arm part, and metal mold for forming the arm part |
-
2005
- 2005-03-31 JP JP2005104889A patent/JP2006281622A/en not_active Withdrawn
-
2006
- 2006-03-31 GB GB0606569A patent/GB2424613B/en not_active Expired - Fee Related
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH06111653A (en) * | 1991-09-28 | 1994-04-22 | Omron Corp | Method for forming insertion part of terminal fitting of electric equipment |
| JPH0780890A (en) * | 1993-09-13 | 1995-03-28 | Ueda Kanagata:Kk | Molding method for synthetic resin product with insert embedded and synthetic resin biological model with insert wire embedded |
| EP1097740A1 (en) * | 1999-05-10 | 2001-05-09 | Takara Co., Ltd. | Arm part for elastic doll body, method of forming the arm part, and metal mold for forming the arm part |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1810810A1 (en) * | 2006-01-18 | 2007-07-25 | Sumitomo Wiring Systems, Ltd. | Moulding construction and a molding method of a resin-molded product |
| US8118583B2 (en) | 2006-01-18 | 2012-02-21 | Sumitomo Wiring Systems, Ltd. | Molding construction and a molding method for a resin-molded product |
| US7776247B2 (en) | 2007-06-04 | 2010-08-17 | Denso Corporation | Method of manufacturing electronic device having resin-molded case and molding tool for forming resin-molded case |
| WO2013144008A1 (en) * | 2012-03-27 | 2013-10-03 | Louise Mohn | Moulding method |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2424613B (en) | 2010-07-28 |
| GB0606569D0 (en) | 2006-05-10 |
| JP2006281622A (en) | 2006-10-19 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20210331 |