JP2006181734A - Method and apparatus for molding insert product, electromagnetic device, discharge lamp lighting device, luminaire and vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding method of an insert product enhanced in the positioning precision of the insert product even if there is irregularity in the outer shape dimension of the insert product and having good productivity, an insert product molding apparatus, an electromagnetic device, a discharge lamp lighting device, a luminaire and a vehicle. <P>SOLUTION: The insert product molding apparatus is constituted so as to perform a process wherein the insert product is arranged between a pair of holding members 51 and 60 within the cavity 40 formed by mating molds 20 and 30 mutually and the holding member 51 arranged in a freely advancing and retreating manner is elastically exerted on the insert product by an elastomer 53 to hold the insert product between both holding members 51 and 60, a process for restricting the holding member 51 arranged in the freely advancing and retreating manner in a state that the insert product is held to fix the position of the holding member 51 and a process for filling the cavity part 40 with a molten resin in a state that the position of the holding member 51 is fixed. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an insert product molding method, an insert product molding device, an electromagnetic device, a discharge lamp lighting device, a lighting fixture, and a vehicle.

  Conventionally, since circuit parts such as coils, transformers, and ICs require insulation and waterproofness, the surface has been covered with a potting material to ensure insulation and waterproofness. And the improvement of recyclability has been strongly demanded, and the surface has been sealed with a molding resin. For this resin sealing, an insert molding method used in injection molding or transfer molding excellent in mass productivity is employed.

  Here, for example, the insert molding described above is performed in a state in which a pair of molds is applied to both sides of an insert product such as a sintered member having a dimensional accuracy variation of about 1 mm, and the pair of molds are abutted through the insert product. When performing, the following problems occur due to variations in the dimensions of the inserts.

  In other words, if the insert product is smaller than the design size, a gap is created between the mold and the insert product, and the resin material is filled in the gap in a burr shape, which may cause a displacement of the insert product. There was sex. In addition, when the insert product is larger than the design size, the insert product is compressed by clamping the die that is abutted through the insert product, so that the insert product may be deformed due to stress. To increase the dimensional accuracy of the insert product in order to make it difficult to cause such problems, post-processing of the insert product is required, resulting in high costs.

Therefore, in order to solve the above-described problems, for example, a molding die as shown in Patent Document 1 has been proposed. The mold shown in Patent Document 1 is for forming an insulating layer on the outside of the coil body around which the winding is wound. The coil body is disposed in a cavity formed by combining the molds, and a spacer is used. After fixing the coil body in the cavity, a molding resin is injected into the cavity to form an insulating layer on the outside of the coil body. Here, the mold is provided with a recess into which a part of the spacer is inserted. By adjusting the depth of the recess, the amount of protrusion of the spacer is adjusted, and the outer dimensions of the coil body are somewhat varied. Also, the coil body is fixed at a desired position.
JP-A-6-238680

  However, in the mold disclosed in Patent Document 1, the depth of the recess (ie, the protrusion amount of the spacer) is measured every time insert molding is performed in order to adjust the depth of the recess. Therefore, there is a problem that the number of man-hours for the molding operation increases and the mass productivity decreases.

  Further, in the mold disclosed in Patent Document 1, in the spacer for fixing the coil body inside the cavity, a part of the side in contact with the mold has good adhesion to the molding resin, and the molding resin and the heat Although it has been proposed to use an elastic body having substantially the same expansion coefficient, if only a part of the spacer is made of an elastic body, when resin molding is performed at a high pressure like injection molding, it is elastic with the resin pressure at the time of molding. Since the body is compressed, there is a gap between the coil body and the spacer, and there is a problem that the gap is filled with molding resin in the gap and the position of the coil body, which is an insert product, is displaced. .

  The present invention has been made in view of the above problems, and the object of the present invention is to provide high positioning accuracy of insert products and good productivity even when there are variations in the outer dimensions of the insert products. The object is to provide an insert product molding method, an insert product molding device, an electromagnetic device, a discharge lamp lighting device, a lighting fixture, and a vehicle.

  In order to achieve the above object, according to the first aspect of the present invention, an insert is disposed between a pair of holding members provided in a mold in a cavity formed by combining a plurality of molds, and a pair of holdings Among the members, at least one holding member can be moved forward and backward in the arrangement direction of the both holding members, and the holding members arranged to move forward and backward are elastically urged toward the insert product side by the elastic urging means. A step of holding the insert product in between, a step of fixing the position of the holding member by restraining the holding member that is disposed so as to be able to move forward and backward while holding the insert product between the holding members, and a position of the holding member And a step of filling the cavity with a molten resin in a fixed state.

  According to the invention of claim 2, an insert product is disposed between a pair of holding members provided in a mold in a cavity formed by combining a plurality of molds, and at least one of the pair of holding members is held. A step of holding the insert product between the two holding members by allowing the member to move forward and backward in the arrangement direction of the both holding members and elastically urging the holding member arranged to advance and retract toward the insert product side by the elastic biasing means. And filling the cavity with molten resin from a gate provided at a part of a portion where the holding member arranged to be movable forward and backward in the mold slides while holding the insert product between the holding members. It is characterized by including.

  The invention of claim 3 is an insert product molding apparatus comprising a plurality of molds and a pair of holding members that project into a cavity formed by combining the plurality of molds and hold the insert product from both sides, Among the pair of holding members, at least one holding member is disposed so as to be movable forward and backward in the arrangement direction of the both holding members, and provided with an elastic biasing means for elastically biasing the holding member disposed so as to be movable forward and backward toward the insert product side. The mold is characterized in that a gate for filling a molten resin is provided in a part of a portion where a holding member arranged to be movable back and forth slides.

  Invention of Claim 4 is an electromagnetic device, Comprising: The winding structure containing a ferrite core, the coil | winding wound around the said ferrite core, and the coil terminal electrically connected to the both ends of the said coil | winding And using a method for forming an insert product according to claim 1 or 2, wherein the winding structure as an insert product is resin-sealed in a state where at least a part of the coil terminal is exposed.

  The invention of claim 5 is a discharge lamp lighting device, wherein the electromagnetic device of claim 4 is used.

  A sixth aspect of the invention is a lighting fixture, wherein the discharge lamp lighting device according to the fifth aspect is used.

  A seventh aspect of the present invention is a vehicle, wherein the lighting fixture according to the sixth aspect is used.

  According to the first aspect of the present invention, at least one of the pair of holding members is disposed so as to be movable forward and backward, and the holding member disposed so as to be movable forward and backward is elastically urged toward the insert product by the elastic urging means. Therefore, the elastic urging means absorbs the variation in the size of the insert product, so that it is possible to prevent a compressive force from being applied to the insert product and the displacement of the insert product from occurring. Moreover, while holding the insert product with the holding member, the holding member arranged to move forward and backward is restrained, and after fixing the position, the cavity is filled with molten resin, so it is arranged to move forward and backward. The holding member does not move backward due to the resin pressure during molding, and the insert can be reliably held at a specified position in the cavity, so that a good molded product can be obtained.

  According to the second aspect of the present invention, at least one of the pair of holding members is disposed so as to be movable forward and backward, and the holding member disposed so as to be movable forward and backward is elastically biased toward the insert product side by the elastic biasing means. Therefore, the elastic urging means absorbs the variation in the size of the insert product, so that it is possible to prevent a compressive force from being applied to the insert product and the displacement of the insert product from occurring. In addition, since a gate is provided at a part of the sliding portion of the holding member arranged so as to be movable forward and backward, and the molten resin is filled into the cavity from this gate, the resin in the direction in which the insert product is pressed against the other holding member at the time of molding. Since pressure is applied to the insert product, resin pressure in a direction away from the insert product is not applied to the holding member disposed so as to be movable forward and backward, and the insert product can be reliably held at a specified position in the cavity. Therefore, a good molded product can be obtained.

  According to the invention of claim 3, at least one of the pair of holding members is disposed so as to be movable forward and backward, and the holding member disposed so as to be movable forward and backward is elastically biased toward the insert product side by the elastic biasing means. As a result, it is possible to realize an insert product forming apparatus that prevents the compressive force from being applied to the insert product and the displacement of the insert product from occurring by absorbing the variation in the size of the insert product. In addition, since a gate is provided at a part of the sliding portion of the holding member arranged so as to be movable forward and backward, and the molten resin is filled into the cavity from this gate, the resin in the direction in which the insert product is pressed against the other holding member at the time of molding. Since pressure is applied to the insert product, resin pressure in a direction away from the insert product is not applied to the holding member disposed so as to be movable forward and backward, and the insert product can be reliably held at a specified position in the cavity. Thus, an insert product molding apparatus capable of resin molding a good molded product can be realized.

  According to the invention of claim 4, by suppressing the displacement of the winding structure that is an insert product, there is no portion where the thickness of the sealing resin for sealing the winding structure becomes extremely thin, A desired dielectric breakdown strength can be obtained, and an electromagnetic device with improved insulation can be provided.

  According to the invention of claim 5, since the electromagnetic structure having a high insulation property with a small positional deviation of the winding structure as an insert product is used, it is possible to provide a discharge lamp lighting device with little variation in quality between products. In addition, even when a high voltage generated during lighting of the discharge lamp is applied to the electromagnetic device, dielectric breakdown does not occur in the electromagnetic device, so that a discharge lamp lighting device capable of obtaining a stable lighting state can be provided.

  According to the sixth aspect of the invention, by using the discharge lamp lighting device according to the fifth aspect, it is possible to provide a highly reliable lighting apparatus with little variation in quality.

  According to the seventh aspect of the present invention, by using the lighting apparatus according to the sixth aspect, it is possible to provide a vehicle having a highly reliable lighting apparatus with little variation in quality.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
An embodiment of an insert product molding apparatus using an insert product molding method according to the present invention will be described with reference to the drawings.

  First, an electromagnetic device manufactured using the insert product forming apparatus of this embodiment will be described. FIG. 15 shows an insert 1 that is resin-sealed with a molding resin. The insert 1 is a round bar-shaped ferrite core 2 and a flat wire 3 is wound around the circumference of the ferrite core 2 by one layer edgewise. And the core holder 4 that holds the ferrite core 2 around which the secondary winding N2 is wound. The core holder 4 includes both ends of the rectangular wire 3 (secondary winding N2). Terminals 5a and 5b electrically and mechanically connected to 3a and 3b are fixed by press-fitting or simultaneous molding. The insert product 1 is resin-sealed with a sealing resin 6 for insulation to form a molded product (high-voltage circuit block 7).

  In the present embodiment, the winding structure is described as an example of the insert product 1. However, the insert product 1 is not intended to be limited to the winding structure, and the electricity embedded in the sealing resin 6 after molding. Any component can be used. In addition, even when an electrical component is embedded in the sealing resin 6, it goes without saying that the terminals 5a and 5b for electrical connection with the outside and portions having no functional problem may be partially exposed. In the insert 1 shown in FIG. 15, the end of the ferrite core 2 on the high pressure side needs to be completely sealed with the sealing resin 6 in order to ensure the insulation performance, but the end surface on the low pressure side is sealed with the sealing resin 6. There is no functional problem even if it is exposed.

  Next, an insert product forming apparatus for manufacturing the electromagnetic device by sealing the insert product 1 with a resin will be described with reference to FIG. The insert product 1 is insert-molded using two molds 20, 30, and both molds 20, 30 are each provided in a mold clamping part (not described in detail) of a conventionally known molding machine 70. The mold platen 71 and the lower mold platen 72 are attached. One mold 20 includes an upper mold plate 21, a runner plate 22, and an upper mold mounting plate 23 as main components, and the other mold 30 includes a lower mold plate 31, a lower mold receiving plate 32, and a lower mold mounting. The board 33 is provided as a main configuration. The molds 20 and 30 are temperature adjusted by temperature adjusting means (fluid circulation, heater, etc.) not shown.

  Cavities 40a and 40b are respectively formed on the mating surfaces of the upper mold plate 21 and the lower mold plate 31, and the insert product 1 is held inside from the two cavities 40a and 40b. A cavity 40 for forming a molded product (high-voltage circuit block 7) by sealing the resin with molten resin 6 is formed. A gate 26 is formed at the right end of the cavity 40 a of the upper mold plate 21.

  Incidentally, FIG. 2 is a cross-sectional view schematically showing the insert 1 described with reference to FIG. 15, in which the terminals 5a and 5b are omitted, and in the following description of the molding method, the outline shown in FIG. The description will be made using the structure. 2 is shown upside down from FIG. 15, and is held in the cavity portion 40 in this state. 2 denotes a high-pressure yoke held by the core holder 4, and the high-pressure yoke 9 is provided with a through hole 9 a for exposing the end face of the ferrite core 2.

  On the mating surfaces of the upper mold plate 21 and the lower mold plate 31, storage concave portions 41a and 42a communicating with the cavities 40a and 40b are formed on the left sides of the cavities 40a and 40b, respectively. Further, the mating surfaces of the upper mold plate 21 and the lower mold plate 31 are accommodated on the right side of the cavities 40a and 40b, respectively, in communication with the cavities 40a and 40b via the sliding grooves 41b and 42b that are recessed in a semicircular shape. Concave portions 41c and 42c are formed.

  One holding member 51 is slidably disposed in the housing recesses 41 a and 42 a, and supports the insert product 1 by contacting one end of the insert product 1. A slide core 52 is slidably disposed in the housing recesses 41a and 42a, and an elastic body 53 (elastic biasing means) such as a coil spring is interposed between the slide core 52 and the holding member 51. It is disguised. Thus, when the molds 20 and 30 are put together, if the slide core 52 is pushed by the upper mold plate 21 and slid to the insert product 1 side, a force for urging the slide core 52 to the insert product 1 side is generated. It is added to the holding member 51 through the elastic body 53, and the holding member 51 slides to the insert product 1 side.

  Further, the other holding member 60 has a round bar shape as shown in FIG. 3, and is slidably disposed in a round hole formed by combining the sliding grooves 41b and 42b. One end side (cavity part 40 side) of the holding member 60 from the axial direction intermediate part is formed by cutting an upper semicircular portion into a semicircular cross section. To tell. A large-diameter head 61 is formed on the other end side of the holding member 60 in the axial direction. The holding member 60 is connected to a rod of an air cylinder 64 through a joint block 63 and is driven in the left-right direction by the air cylinder 64. The joint block 63 includes two front and rear halves, and the holding member 60 is connected to the joint block 63 by sandwiching the head 61 of the holding member 60 between the two halves. The holding member 60 may have a square bar shape, or the holding member 60 may be driven by a hydraulic cylinder or a motor.

  Here, the molten resin melted at the injection portion (not shown) of the molding machine 70 is fed from the molding machine nozzle 73 to the upper die mounting plate 23 and the runner plate 22 through the sprue 24 and the upper die plate. 21 is introduced into the cavity portion 40 through the runner 25 and the gate 26 formed in 21. In this embodiment, the case of injection molding is shown, but the present invention can also be applied to a molding method such as a transfer molding machine. Moreover, although this embodiment showed the case of the vertical type | molding machine, it cannot be overemphasized that it is applicable also in the case of a horizontal type.

  Hereinafter, an insert product molding method in which the insert product 1 is sealed with a molten resin using the insert product molding apparatus will be described with reference to FIGS. 4 to 8, the upper mold platen 71, the lower mold platen 72, the molding machine nozzle 73, and the air cylinder 64 are omitted in order to simplify the description.

  First, as shown in FIG. 4, the insert 1 is placed in the cavity 40 b of the mold 30 with the mold 20 lifted upward. At this time, the temporary holding members 43 and 44 are raised, and the tips thereof are in contact with the winding 3 and the high voltage yoke 9 of the insert 1, and the core holding portion 31 a provided on the lower mold plate 31 is provided with the ferrite core 2. The insert product 1 is temporarily held in contact with the low-pressure side end portion. The temporary holding member 43 is a pin having a head 43b at the lower end of the shaft 43a, and is supported by the return plates 45a and 45b by sandwiching the head 43b between the two return plates 45a and 45b. ing. The return plates 45a and 45b are disposed in a recess 32a provided in the lower mold receiving plate 32 so as to be movable up and down, and are biased upward by springs 46 and 46, whereby the temporary holding member 43 moves upward. ing. The temporary holding member 44 is also composed of a pin having a head portion 44a provided at the lower end of the shaft portion, and is disposed so as to be movable up and down with the head portion 44a placed in a recess provided in the lower mold plate 31, The spring 47 is biased upward by the spring force. The holding member 60 is moved to a position retracted from the cavity 40b by the air cylinder 64.

  Next, when the rod 65 of the air cylinder 64 advances as shown in FIG. 5, the holding member 60 advances, and the tip of the holding member 60 engages with the engagement recess 2 a provided at the high-pressure side end of the ferrite core 2. Match.

  Thereafter, the upper mold plate 21 is lowered by a mold opening / closing device (not shown) of the molding machine, and the upper mold plate 21 and the lower mold plate 31 are closed as shown in FIG. When the surface 52a hits the contact portion 21b provided on the upper mold plate 21, the slide core 52 advances toward the cavity portion 40 side. At this time, the pressing force of the slide core 52 is applied to the holding member 51 via the elastic body 53, the holding member 51 advances toward the cavity portion 40, and the support protrusion 51 a of the holding member 51 is the low-pressure side end of the ferrite core 2. It engages with the engaging recess 2b provided in the. Although the engagement recesses 2a and 2b are formed in a conical shape, the engagement recess 2b may have a pyramid shape or a hemispherical shape.

  At this time, the pair of holding members 51 and 60 are in a state of being abutted via the insert product 1 (ferrite core 2), and the insert product 1 is sandwiched between the holding members 51 and 60, so that the insert product 1 is Positioned in the left-right direction. Here, an elastic body 53 is interposed between the holding member 51 and the slide core 52, and the holding member 51 is elastically biased toward the insert product 1 by the elastic body 53, so that the insert product 1 ( Even if the longitudinal dimension of the ferrite core 2) varies somewhat, the variation in the longitudinal dimension can be absorbed by the elastic body 53 expanding and contracting. Therefore, when the insert product 1 is held between the holding members 51 and 60, a compressive force is applied to the insert product 1, or a gap is formed between the insert product 1 and the holding members 51 and 60. It can be prevented from occurring.

  At the same time, the core holding portions 21a and 31a provided on the upper mold plate 21 and the lower mold plate 31 hold the ferrite core 2 so as to sandwich the peripheral surface of the ferrite core 2 from both the upper and lower sides. The end of the product 1) on the low pressure side is held with high accuracy. The holding member 51 may be moved forward and backward using an actuator such as an air cylinder, as with the holding member 60.

  As shown in FIG. 6, when the upper mold plate 21 and the lower mold plate 31 are closed and the proximity switch SW incorporated in the lower mold plate 31 detects the mold closing, the mold opening / closing device of the molding machine again closes the mold. As shown in FIG. 7, the runner plate 22 comes into contact with the upper mold plate 21 to complete the mold closing. At this time, the holding member 51 is sandwiched between the upper mold plate 21 and the lower mold plate 31, and when the mold closing is completed and a mold clamping force is applied to the molds 20, 30, both mold plates 21. 31, the holding member 51 is firmly restrained and the position of the holding member 51 is fixed, so that the insert product 1 is fixed while being held between the holding members 51, 60. At the same time, the upper die return pin 27 attached to the runner plate 22 pushes down the lower die return pin 34 attached so as to be sandwiched between the return plates 45a and 45b similarly to the temporary holding member 43. 45a, 45b descends against the spring force of the spring 46, and the temporary holding member 43 also descends and retracts from the cavity portion 40 accordingly, so that the temporary holding by the temporary holding member 43 is completed. Then, since the insert product 1 is firmly held between the holding members 51 and 60, the position of the insert product 1 is not shifted.

  When the mold clamping is completed and the mold clamping is completed by the mold clamping force of the molding machine, the resin material (molten resin 6) melted from the molding machine nozzle 73 passes through the sprue 24, the runner 25, and the gate 26 as shown in FIG. 40 is filled. At this time, since the spring force of the spring 46 that biases the temporary holding member 44 upward is set smaller than the resin pressure in the cavity portion 40, the temporary holding member 44 is lowered by the resin pressure, and the cavity portion 40. Therefore, the temporary holding by the temporary holding member 44 ends. Since the temporary holding member 44 moves backward due to the resin pressure in this manner, the positioning accuracy of the insert product 1 is improved by temporarily holding the holding member 51 before holding the holding member 51 without requiring a separate driving source. Can be made.

  Then, before completion of filling the molten resin 6 into the cavity 40 or after completion of filling, the control unit detects the predetermined timing when the molten resin 6 encloses at least a part of the periphery of the insert product 1 and the control unit When the cylinder 64 is driven to retract the rod 65, the holding member 60 is retracted from the cavity portion 40. Here, even if the holding member 60 is retracted from the cavity portion 40, since the molten resin 6 encloses the periphery of the insert product 1, the displacement of the insert product 1 occurs due to the resin pressure of the molten resin 6. There is no.

  After that, when the time required for the molten resin 6 filled in the cavity portion 40 to solidify or harden sufficiently has elapsed due to the timer setting of the molding machine, the mold 20 is raised by the mold opening / closing device of the molding machine, and the two molds The molds 20 and 30 are opened. At this time, since the holding member 51 is not pressed forward by the contact portion 21b of the upper mold plate 21, the holding member 51 is retracted by a retraction spring (not shown) and is separated from the end face of the ferrite core 2. When the retraction of the holding member 51 is completed, the ejecting device (not shown) of the molding machine is driven, and the molded product (high-voltage circuit block 7) is moved by the ejector pin (not shown) in the mold 30. It can be ejected from the plate 31 and taken out.

  As described above, in the insert product molding method of the present embodiment, the pair of holding members 51, 60 is formed in the cavity portion 40 formed by combining a plurality of (two in the present embodiment) molds 20, 30. The insert product 1 is disposed between them, and at least one of the pair of holding members 51 and 60 is movable forward and backward in the arrangement direction of the both holding members 51 and 60. In a state where the insert product 1 is held between the holding members 51, 60 by holding the insert product between the holding members 51, 60 by elastically urging the insert product 1 side by the elastic body 53. A step of fixing the position of the holding member 51 by firmly holding the holding member 51 arranged so as to be able to advance and retreat between both mold plates 21 and 31, and a state where the position of the holding members 51 and 60 is fixed. And filling the molten resin 6 into the portion 40, and even if there is some variation in the outer dimensions of the insert product 1, the elastic body 53 can expand and contract to absorb the variation in the outer dimensions, It is possible to prevent a compressive force from being applied to the insert product 1 and a gap between the insert product 1 and the holding members 51 and 60 to be generated and the displacement of the insert product 1 from occurring. Moreover, since the insert member 1 is held by the holding member 51, the holding member 51 disposed so as to be able to advance and retreat is restrained and the position is fixed, and then the molten resin 6 is filled in the cavity portion 40. The holding member 51 does not move backward due to the resin pressure at the time of molding, and the insert product 1 can be reliably held at a specified position in the cavity portion 40, so that a good molded product can be obtained. .

  Here, the above-described insert product 1 is a winding structure, and the positional displacement of the winding structure is reduced by resin-sealing the winding structure using the insert product molding method of the present embodiment. Can do. Therefore, when this winding structure is resin-sealed, there is no portion where the thickness of the sealing resin becomes extremely thin, so that a desired dielectric breakdown strength can be obtained and an electromagnetic device with improved insulation is provided. can do.

  In the present embodiment, the pair of holding members 51 and 60 are both movably disposed. However, only one holding member 51 elastically biased by the elastic body 53 may be slidable. In this embodiment, the holding members 51 and 60 slide and move in a direction perpendicular to the opening and closing direction of the mold (side core structure). However, the opening and closing direction of the mold and the movement of the holding members 51 and 60 are the same. The direction may be the same direction.

(Embodiment 2)
Another embodiment of the insert product molding apparatus using the insert product molding method according to the present invention will be described with reference to the drawings. The insert product 1 and the electromagnetic device manufactured by insert molding the insert product 1 are the same as the insert product 1 and the electromagnetic device shown in FIG.

  Next, an insert product forming apparatus for manufacturing the electromagnetic device shown in FIG. 15 by sealing the insert product 1 with a resin will be described with reference to FIG. The insert product 1 is insert-molded using two molds 20, 30, and both molds 20, 30 are each provided in a mold clamping part (not described in detail) of a conventionally known molding machine 70. The mold platen 71 and the lower mold platen 72 are attached. One mold 20 includes an upper mold plate 21, a runner plate 22, and an upper mold mounting plate 23 as main components, and the other mold 30 includes a lower mold plate 31, a lower mold receiving plate 32, and a lower mold mounting. The board 33 is provided as a main configuration. The molds 20 and 30 are temperature adjusted by temperature adjusting means (fluid circulation, heater, etc.) not shown.

  Cavities 40a and 40b are respectively formed on the mating surfaces of the upper mold plate 21 and the lower mold plate 31, and the insert product 1 is held inside from the two cavities 40a and 40b. A cavity 40 for forming a molded product (high-voltage circuit block 7) by sealing the resin with molten resin 6 is formed.

  On the mating surfaces of the upper mold plate 21 and the lower mold plate 31, storage concave portions 41a and 42a communicating with the cavities 40a and 40b are formed on the left sides of the cavities 40a and 40b, respectively. Further, the mating surfaces of the upper mold plate 21 and the lower mold plate 31 are accommodated on the right side of the cavities 40a and 40b, respectively, in communication with the cavities 40a and 40b via the sliding grooves 41b and 42b that are recessed in a semicircular shape. Concave portions 41c and 42c are formed.

  A holding member 51 is slidably disposed in the housing recesses 41 a and 42 a, and the holding member 51 supports the insert product 1 by abutting against one end of the insert product 1. A slide core 52 is slidably disposed in the storage recesses 41a and 42a. The slide core 52 receives a pressing force from the upper mold plate 21 when the molds are put together, and inserts the holding member 51 into the insert. Drive to the product 1 side.

  The other holding member 60 has a substantially round bar shape, and is slidably disposed in a round hole formed by combining the sliding grooves 41b and 42b. One end side (cavity part 40 side) of the holding member 60 from the axial direction intermediate part is formed by cutting an upper semicircular portion into a semicircular cross section. To tell. A large-diameter head 61 is formed on the other end side of the holding member 60 in the axial direction. The holding member 60 is connected to a rod of an air cylinder 64 through a joint block 63 and is driven in the left-right direction by the air cylinder 64. The joint block 63 includes two front and rear halves, and is attached to the recess 63a formed by combining the two halves so that the head 61 of the holding member 60 is placed in the left and right direction so as to be freely movable. The holding member 60 is elastically urged toward the insert product 1 by pressing the head 61 toward the insert product 1 with an elastic body (elastic urging means) 66 such as a coil spring disposed in 63a. The holding member 60 may have a square bar shape, or the holding member 60 may be driven by a hydraulic cylinder or a motor.

  Here, the exit of the gate 26 faces the space formed by the D-cut portion 62 and the sliding grooves 41b and 42b, which is a sliding portion of the holding member 60, and the molten resin that has passed through the gate 26 is removed from the cavity. This is a flow path for introduction into the portion 40. That is, the molten resin melted at the injection portion (not shown) of the molding machine 70 is passed from the molding machine nozzle 73 to the sprue 24 penetrating the upper mold mounting plate 23 and the runner plate 22 and the upper mold plate 21. Then, it passes through the runner 25 and the gate 26 formed in the above, and further passes through a space formed by the D-cut portion 62 and the sliding grooves 41b and 42b of the holding member 60 and is introduced into the cavity portion 40. In this embodiment, the case of injection molding is shown, but the present invention can also be applied to a molding method such as a transfer molding machine. Moreover, although this embodiment showed the case of the vertical type | molding machine, it cannot be overemphasized that it is applicable also in the case of a horizontal type.

  Hereinafter, an insert product molding method in which the insert product 1 is sealed with a molten resin using the insert product molding apparatus will be described with reference to FIGS. 10 to 14, the upper mold platen 71, the lower mold platen 72, the molding machine nozzle 73, and the air cylinder 64 are omitted in order to simplify the description.

  First, as shown in FIG. 10, the insert 1 is placed in the cavity 40 b of the mold 30 with the mold 20 lifted upward. At this time, the temporary holding members 43 and 44 are raised, and the tips thereof are in contact with the winding 3 and the high voltage yoke 9 of the insert 1, and the core holding portion 31 a provided on the lower mold plate 31 is provided with the ferrite core 2. The insert product 1 is temporarily held in contact with the low-pressure side end portion. The temporary holding member 43 is a pin having a head 43b at the lower end of the shaft 43a, and is supported by the return plates 45a and 45b by sandwiching the head 43b between the two return plates 45a and 45b. ing. The return plates 45a and 45b are disposed in a recess 32a provided in the lower mold receiving plate 32 so as to be movable up and down, and are biased upward by springs 46 and 46, whereby the temporary holding member 43 moves upward. ing. The temporary holding member 44 is also composed of a pin having a head portion 44a provided at the lower end of the shaft portion, and is disposed so as to be movable up and down with the head portion 44a placed in a recess provided in the lower mold plate 31, The spring 47 is biased upward by the spring force. The holding member 60 is moved to a position retracted from the cavity 40b by the air cylinder 64.

  Next, when the upper mold plate 21 is lowered by a mold opening / closing device (not shown) of the molding machine and the upper mold plate 21 and the lower mold plate 31 are closed as shown in FIG. When the inclined surface 52a hits the contact portion 21b provided on the upper mold plate 21, the slide core 52 advances toward the cavity portion 40. At this time, the pressing force of the slide core 52 is applied to the holding member 51, the holding member 51 advances toward the cavity portion 40, and the engagement protrusion 51 a of the holding member 51 is provided at the low-pressure side end of the ferrite core 2. Engage with 2b. At the same time, the core holding portions 21a and 31a provided in the upper mold plate 21 and the lower mold plate 31 hold the ferrite core 2 so as to sandwich the peripheral surface of the ferrite core 2 from both the upper and lower sides. The end of the insert 1) on the low pressure side is held. The slide core 50 and the holding member 51 may be moved forward and backward using an actuator such as an air cylinder in the same manner as the holding member 60.

  When the proximity switch SW incorporated in the lower mold plate 31 detects the closing of the mold, a control unit (not shown) drives the air cylinder 64 and advances the rod 65 in accordance with the detection signal of the proximity switch SW. As shown, the holding member 60 connected to the rod 65 via the joint block 63 advances into the cavity 40 and engages with the engagement recess 2 a provided at the high-pressure end of the ferrite core 2.

  At this time, the pair of holding members 51 and 60 are in a state of being abutted via the insert product 1 (ferrite core 2), and the insert product 1 is sandwiched between the holding members 51 and 60, so that the insert product 1 is Positioned in the left-right direction. Here, the holding member 60 is attached to the molds 20 and 30 so as to be able to advance and retreat in the left-right direction, and is elastically biased toward the insert product 1 by the elastic body 66. Even if there is a variation, the elastic body 66 can be expanded and contracted to absorb variations in longitudinal dimensions. Therefore, when the insert product 1 is held between the holding members 51 and 60, a compressive force is applied to the insert product 1, or a gap is formed between the insert product 1 and the holding members 51 and 60. It can be prevented from occurring.

  When the rod 65 of the air cylinder 64 moves forward and the tip of the rod 65 is in contact with the high-pressure side end of the ferrite core 2 using a conventionally known detection means, the mold opening and closing device of the molding machine starts the mold closing again. Then, as shown in FIG. 13, the runner plate 22 contacts the upper mold plate 21, and the mold closing is completed. When the mold closing is completed, the upper mold return pin 27 attached to the runner plate 22 pushes down the lower mold return pin 34 attached so as to be sandwiched between the return plates 45a and 45b in the same manner as the temporary holding member 43. The return plates 45a and 45b are lowered against the spring force of the spring 46, and the temporary holding member 43 is also lowered and retracted from the cavity portion 40 accordingly, so that the temporary holding by the temporary holding member 43 is completed. At this time, since the insert product 1 is firmly held between the holding members 51 and 60, the position of the insert product 1 does not shift.

  When the mold clamping is completed and the mold clamping is completed by the mold clamping force of the molding machine, the resin material (molten resin 6) melted from the molding machine nozzle 73 is sprue 24, runner 25, gate 26, and holding as shown in FIG. The cavity portion 40 is filled through a space formed by the D-cut portion 62 of the member 60 and the sliding grooves 41b and 42b.

  Here, the exit of the gate 26 faces a space formed by the D-cut portion 62 and the sliding grooves 41b and 42b of one holding member 60, and the cavity portion 40 is filled with molten resin through the gate 26. Therefore, since a force in a direction to press the insert 1 against the other holding member 51 is applied to the holding member 51 at the time of resin filling, the elastic body 66 that elastically biases one holding member 60 has a resin filling pressure. Will not bend by. Therefore, the holding member 60 does not move due to the resin filling pressure, and a gap is formed between the insert product 1 and the holding member 60, so that the displacement of the insert product 1 can be prevented. A molded product can be formed.

  Further, since the spring force of the spring 46 that biases the temporary holding member 44 upward is set smaller than the resin pressure in the cavity portion 40, the temporary holding member 44 is lowered by the resin pressure, and the cavity portion 40 Since it moves backward, the temporary holding by the temporary holding member 44 ends. Since the temporary holding member 44 moves backward due to the resin pressure in this manner, the positioning accuracy of the insert product 1 is improved by temporarily holding the holding member 51 before holding the holding member 51 without requiring a separate driving source. Can be made.

  Then, before completion of filling the molten resin 6 into the cavity 40 or after completion of filling, the control unit detects the predetermined timing when the molten resin 6 encloses at least a part of the periphery of the insert product 1 and the control unit When the cylinder 64 is driven to retract the rod 65, the holding member 60 is retracted from the cavity portion 40. Here, even if the holding member 60 is retracted from the cavity portion 40, since the molten resin 6 encloses the periphery of the insert product 1, the displacement of the insert product 1 occurs due to the resin pressure of the molten resin 6. There is no.

  After that, when the time required for the molten resin 6 filled in the cavity portion 40 to solidify or harden sufficiently has elapsed due to the timer setting of the molding machine, the mold 20 is raised by the mold opening / closing device of the molding machine, and the two molds The molds 20 and 30 are opened. At this time, since the holding member 51 is not pressed forward by the contact portion 21b of the upper mold plate 21, the holding member 51 is retracted by a retraction spring (not shown) and is separated from the end face of the ferrite core 2. When the retraction of the holding member 51 is completed, the ejecting device (not shown) of the molding machine is driven, and the molded product (high-voltage circuit block 7) is moved by the ejector pin (not shown) in the mold 30. It can be ejected from the plate 31 and taken out.

  As described above, in the insert product molding method of the present embodiment, the pair of holding members 51, 60 is formed in the cavity portion 40 formed by combining a plurality of (two in the present embodiment) molds 20, 30. The insert product 1 is disposed between them, and at least one of the pair of holding members 51 and 60 is movable forward and backward in the arrangement direction of the both holding members 51 and 60. In a state where the insert product 1 is held between the holding members 51, 60 by holding the insert product between the holding members 51, 60 by elastically urging the insert product 1 side by the elastic body 53. The molten resin 6 is filled into the cavity portion 40 from the gate 26 provided at a part of the portion (sliding groove 41b) where the holding member 60 slidably disposed in the mold 20 slides. Even if there is some variation in the outer dimensions of the insert product 1, the elastic body 66 can be expanded and contracted to absorb the variation in outer dimensions, and a compressive force is applied to the insert product 1. It is possible to prevent the insert product 1 from being displaced due to a gap between the insert product 1 and the holding members 51 and 60. In addition, in a state where the insert product 1 is held between the holding members 51 and 60, the molten resin enters the cavity portion 40 from the gate 26 provided in a part of the portion (sliding groove 41b) where the holding member 60 slides. 6, the elastic body 66 is not bent due to the resin pressure at the time of molding, and therefore the holding member 60 does not move due to the resin pressure. It can hold | maintain reliably in an inside specified position, and a favorable molded product can be obtained.

  Here, the above-described insert product 1 is a winding structure, and the positional displacement of the winding structure is reduced by resin-sealing the winding structure using the insert product molding method of the present embodiment. Can do. Therefore, when this winding structure is resin-sealed, there is no portion where the thickness of the sealing resin becomes extremely thin, so that a desired dielectric breakdown strength can be obtained and an electromagnetic device with improved insulation is provided. can do.

  In the present embodiment, the pair of holding members 51 and 60 are both movably disposed. However, only one holding member 60 elastically biased by the elastic body 66 may be slidable. In this embodiment, the holding members 51 and 60 slide and move in a direction perpendicular to the opening and closing direction of the mold (side core structure). However, the opening and closing direction of the mold and the movement of the holding members 51 and 60 are the same. The direction may be the same direction.

  In addition, the molten resin 6 used in the above-described Embodiments 1 and 2 is polypropylene, polyethylene having a low thermoplastic melting temperature, polyphthalamide having a high melting temperature, polyetherimide, liquid crystal polyester, syndiotactic polystyrene, or heat. Various resin materials such as curable phenol, epoxy, and unsaturated polyester can be used.

  By the way, the molded product (high-pressure circuit block 7) insert-molded by using the insert-product molding method described in the first and second embodiments applies a high-pressure pulse to the discharge lamp in order to start a discharge lamp such as a metal halide lamp. Used for the discharge lamp starting device A. In the discharge lamp starting device A, as shown in FIG. 17, a pulse transformer PT in which one end of the secondary winding N2 is connected to one electrode of the discharge lamp La and a primary winding N1 of the pulse transformer PT are connected in series. And a pulse generating capacitor C1 connected between both ends of a series circuit including the primary winding N1 and the discharge gap SG. When the capacitor C1 is charged by the inverter INV and the voltage across the capacitor C1 reaches a predetermined voltage, the discharge gap SG is discharged and a current flows through the primary winding N1 of the pulse transformer PT. At this time, a high-pressure pulse is generated in the secondary winding N2 of the pulse transformer PT, and this high-pressure pulse is applied to the discharge lamp La to start the discharge lamp La and receive the power supply from the inverter INV to receive the discharge lamp La. Lights up.

  FIG. 16 shows each manufacturing process of the discharge lamp starting device A. As shown in FIG. 16 (a), the capacitor C1, the discharge gap SG, and the inverter INV are connected to the substrate 11 made of a printed wiring board or a lead frame. The connector CN is mounted to constitute the low voltage circuit block 12 and the winding 8 is provided on the outer peripheral surface of the low voltage side end of the high voltage circuit block 7 (that is, the surface of the sealing resin covering the low voltage side end of the ferrite core 2). An inner electrode 14 and an outer electrode that are wound to form the primary winding N1 and are electrically connected to the center electrode and the outer electrode of the discharge lamp La to the socket port 13 provided integrally with the high-voltage circuit block 7, respectively. 15 is held. Then, after mounting the high-voltage circuit block 7 on the substrate 11 of the low-voltage circuit block 12 as shown in FIG. 4B, the upper surface cover 16 and the lower surface cover 17 made of a synthetic resin molded product are mounted to ensure insulation. Then, the space surrounded by the covers 16 and 17 is partially or entirely filled with an insulating resin such as silicon, and further covered with the upper shield cover 18 and the lower shield cover 19 from both the upper and lower sides to suppress noise, The assembly of the discharge lamp starting device A is completed (see (c) in the same figure).

  The discharge lamp starting device A is configured as described above, and even if a high voltage is applied at the time of starting the discharge lamp La, the dielectric breakdown is achieved by using the above-described molded product with high insulation performance (the high pressure circuit block 7). Does not occur and no lighting does not occur, so that a stable lighting state can be obtained. The top cover 16 and the top shield cover 18 are formed with round hole-shaped opening windows 16a and 18a for exposing the socket opening 13, and the cap of the discharge lamp La can be mounted through the opening windows 16a and 18a. ing.

  The discharge lamp starting device A applies a high-pressure pulse to the discharge lamp La in order to start a discharge lamp La composed of an HID lamp such as a metal halide lamp, and the discharge lamp lighting using the discharge lamp starting device A is performed. A block diagram of apparatus B is shown in FIG. The discharge lamp lighting device B includes an inverter INV that converts a DC voltage of a DC power source E into a rectangular wave voltage and supplies the rectangular wave voltage to a discharge lamp La mounted on the discharge lamp starting device A, and a high-pressure pulse included in the discharge lamp starting device A. The generator is composed of a charging capacitor C1, a discharge gap SG, and a pulse transformer PT. Since the discharge lamp lighting device B uses the above-described discharge lamp starting device A with little variation in quality and high reliability, it is possible to realize a discharge lamp lighting device with high reliability and stable quality.

  FIG. 18 shows an embodiment of a vehicle headlamp fixture C using the above-described discharge lamp lighting device B. The headlamp fixture C is placed inside the lamp housing 101 fixed to the vehicle body. The discharge lamp starting device A and the reflecting plate 102 are accommodated, and a lens 103 is attached to an opening provided on the front surface of the lamp housing 101. An opening 104 for replacing the discharge lamp La is provided at the rear of the lamp housing 101, and a cap 105 is attached to the opening 104 so as to be freely opened and closed. Further, an inverter INV that operates by receiving power supply from the DC power source E is attached to the lower portion of the lamp housing 101, and an electric wire 106 from the inverter INV is connected to the connector CN of the discharge lamp starting device A. ing. Reference numeral 107 in the figure denotes a connection connector for connecting a power supply line from the DC power source E. This headlamp fixture C is configured using the above-mentioned discharge lamp lighting device B. If this headlamp fixture C is used for a vehicle headlamp, there is little variation in quality, and a highly reliable headlamp is provided. realizable. Note that the lighting fixture is not limited to the headlamp C, and the above-described discharge lamp lighting device B may be used to configure a lighting fixture used for a light source of a projector, for example.

  FIG. 19 shows an embodiment of a vehicle D using the above-described vehicle headlamp fixture C. One vehicle headlamp fixture C is attached to each of the left and right sides of the front surface of the vehicle body 110. This vehicle D uses the above-mentioned vehicle headlamp fixture C, and there is little variation in quality, and by using the highly reliable headlamp fixture C, the vehicle D has high safety and quality in night driving. A stable vehicle can be realized.

It is sectional drawing which can abbreviate | omit a part of insert product shaping | molding apparatus using the insert product shaping | molding method of Embodiment 1. FIG. It is sectional drawing which showed typically the insert goods formed using the same as the above. It is an external appearance perspective view of the holding member used for the same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing which can abbreviate | omit a part of insert product shaping | molding apparatus using the insert product shaping | molding method of Embodiment 2. FIG. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is explanatory drawing of each manufacturing process of the high voltage circuit block formed using the same as the above. It is explanatory drawing of each manufacturing process of the discharge lamp starter using a high voltage circuit block same as the above. It is a block circuit diagram of the discharge lamp lighting device using the same. It is sectional drawing of the vehicle headlamp fixture using the same as the above. It is a principal part perspective view of the vehicle using the same as the above.

Explanation of symbols

20, 30 Mold 40 Cavity 51, 60 Holding member 53 Elastic body

Claims (7)

In a cavity formed by combining a plurality of molds, an insert product is arranged between a pair of holding members provided on the mold, and at least one holding member of the pair of holding members is arranged in both holding members. A step of holding the insert product between both holding members by elastically biasing the holding member arranged to be movable forward and backward in the direction and elastically biasing the holding member arranged toward the insert product side by an elastic biasing means;
A step of restraining a holding member arranged so as to be able to advance and retreat in a state where an insert product is held between both holding members and fixing the position of the holding member;
And a step of filling the cavity with a molten resin in a state where the position of the holding member is fixed. In a cavity formed by combining a plurality of molds, an insert product is arranged between a pair of holding members provided on the mold, and at least one holding member of the pair of holding members is arranged in both holding members. A step of holding the insert product between both holding members by elastically biasing the holding member arranged to be movable forward and backward in the direction and elastically biasing the holding member arranged toward the insert product side by an elastic biasing means;
A step of filling the cavity with a molten resin from a gate provided at a part of a portion where a holding member arranged so as to freely move back and forth in the mold in a state where the insert product is held between both holding members. A method for forming an insert product, comprising:   A plurality of molds and a pair of holding members that protrude into a cavity formed by combining the plurality of molds and hold the insert from both sides, and at least one of the pair of holding members Are arranged so as to be able to advance and retreat in the arrangement direction of both holding members, and provided with elastic urging means for elastically urging the holding member arranged to be able to advance and retreat toward the insert product side. An insert product molding apparatus comprising a gate for filling a molten resin in a part of a portion where a holding member slides.   The insert product according to claim 1, comprising a winding structure including a ferrite core, a winding wound around the ferrite core, and a coil terminal electrically connected to both ends of the winding. An electromagnetic device, wherein the winding structure, which is an insert product, is resin-sealed using a molding method with at least a part of the coil terminal exposed.   A discharge lamp lighting device using the electromagnetic device according to claim 4.   A lighting fixture using the discharge lamp lighting device according to claim 5.   A vehicle using the lighting apparatus according to claim 6.

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