JP2009226659A - Control component for internal-combustion engine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive control component for internal-combustion engines having high productivity and reliability. <P>SOLUTION: In the control component for internal-combustion engines, terminals for external connection are formed so as to be integrated with the exterior, electronic components, etc. arranged inside are molded with a molding resin. The exterior is formed in two or more separated molding steps. The resins used in preceding steps are lower in crystallinity than those used in following steps: linear expansion coefficients of the resins approximate; irregularities are formed on the outer peripheral surface; and the surface areas of components formed in following steps is greater than those of parts formed in preceding steps. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a control part for an internal combustion engine, and more particularly to the structure of a control part for an internal combustion engine by multicolor molding.

  FIG. 6 is a longitudinal sectional view of an ignition coil for an internal combustion engine according to the prior art, FIG. 7 is a view of an igniter exterior according to the prior art, and a diagram of a first molding stage of the igniter exterior to which the prior art is applied. It is shown in FIG. In FIG. 6, a conventional internal combustion engine ignition coil 1 includes an upper igniter 20 and a cylindrical coil portion. The coil portion is configured by a core 11 and a primary coil 12 and a secondary coil 13 that are coaxially connected to the core 11 and electromagnetically coupled by the core 11 and accommodated in a cylindrical case 14. An igniter 20 is connected to a switching element (not shown) and an external connection for supplying an ignition signal to the switching element (not shown) for controlling the switching of the primary coil current. An igniter exterior 21 that houses the terminal 22 and accommodates them is provided. An igniter 20 is configured by molding an electronic component or the like mounted with a switching element disposed inside the igniter exterior 21 with an epoxy resin 25.

  7 to 8, the igniter exterior 21 is manufactured by plastic injection molding, and has a tie bar cut hole 24 opened so that a part of the external connection terminal 22 is exposed. After insert molding 22, unnecessary terminals are cut by tie bar cut from tie bar cut holes 24 and sealed by performing additional injection molding. Alternatively, the igniter exterior 21 is sealed by pouring an epoxy resin 25 into the tie bar cut hole 24 after mounting an electronic component or the like.

In addition to the above igniter exterior, in Japanese Patent Laid-Open No. 11-076687 (Patent Document 1), a metal terminal is supported by a support (primary molded product) and a resin covering the support (secondary molded product). Japanese Unexamined Patent Publication No. 11-019937 (Patent Document 2) discloses a molded product in which a primary molded product is arranged on the inner side of the secondary molding surface. In JP-A-2001-293744 (Patent Document 3), after a plurality of insert parts are integrated with a primary resin in a primary molding die, a plurality of insert parts are separated in a parting process. Insert components that are separated from the material and that are integrated with the secondary resin in the secondary molding process and integrated with the secondary resin in the secondary molding die to produce an insert molded product. Process for the production of goods have been disclosed.
Japanese Patent Laid-Open No. 11-076687 Japanese Patent Application Laid-Open No. 11-019937 JP 2001-293744 A

  However, in the igniter in which the ignition coil and the external connection terminal 22 according to the prior art are formed integrally with the igniter exterior 21 and the electronic components and the like arranged inside are molded with the epoxy resin 25, the insert molding is performed as described above. It is necessary to seal the tie bar cut hole 24 after the tie bar cut of the external connection terminal 22, and the method of pouring the epoxy resin 25 into the tie bar cut hole 24 after mounting an electronic component or the like causes the work to be reversed, epoxy, etc. The introduction of resin injection, curing, and drying processes, and the problem that man-hours are very expensive.

  Further, in order to avoid sealing of the tie bar cut hole 24 in a later process, there is a method of filling a hole in advance by additional injection molding. In that case, the resin molded by the additional injection molding and the igniter exterior 21 The molding resin 23 had poor adhesion to each other, and had problems such as a decrease in insulation from the molding interface. The reason is that the igniter exterior 21 molded before filling the hole is produced under ideal molding conditions, but in this case, the crystallization of the resin surface of the igniter exterior 21 has progressed, and an additional injection is performed. Even if an attempt is made to secure adhesion by melting the resin surface of the igniter case 21 at the molding resin temperature, the crystallization of the igniter case 21 has already progressed, and the melting of the resin in the igniter case 21 is hindered. It was a factor that could not secure a good adhesion. In order to increase the adhesion between the molded resin 23 molded as the igniter exterior 21 and the additionally molded resin, crystallization of the resin surface of the igniter exterior 21 may be suppressed, but at the same time, the igniter exterior 21 is ideal. Therefore, the mechanical and physical characteristics as the igniter exterior 21 cannot be sufficiently secured.

  Further, in Patent Documents 1, 2, and 3 described above, there are no descriptions regarding measures for preventing crystallization of the resin surface of the igniter exterior from progressing, the material of the molded product, molding conditions, and the like.

  In order to solve the above problems, the present invention has the following configuration. That is, according to the first aspect of the present invention, in the internal combustion engine ignition device in which the external connection terminal is formed integrally with the exterior and the electronic components and the like disposed inside are molded with the mold resin, the exterior is multiple times from the first molding stage. It is set as the control part for internal combustion engines characterized by having produced by performing in the molding stage divided into.

  According to a second aspect of the present invention, the molding step divided into a plurality of times is N times (N ≧ 2), n is an arbitrary natural number satisfying n∈N, and the resin in the n−1 molding step is the nth molding step. The control component for an internal combustion engine according to claim 1, wherein the control component is of a low crystallization type than the resin in the stage.

  According to a third aspect of the present invention, the molding step divided into a plurality of times is N times (N ≧ 2), n is an arbitrary natural number satisfying n∈N, and the resin in the n−1 molding step and the nth molding step The control part for an internal combustion engine according to claim 2, wherein the resin in the stage has an approximate linear expansion coefficient.

  Further, in claim 4, the molding step divided into a plurality of times is N times (N ≧ 2), n is an arbitrary natural number of n∈N, and the resin in the (n-1) th molding step is The control part for an internal combustion engine according to claim 1, wherein unevenness is formed.

  Further, in claim 5, the molding step divided into the plurality of times is N times (N ≧ 2), and a part molded in each of the previous stages is covered with a part molded in the Nth molding stage, 2. The control part for an internal combustion engine according to claim 1, wherein the surface area of the portion formed in the N forming step is larger than the surface area of the portion formed in each of the previous steps.

  According to a sixth aspect of the present invention, there is provided the control component for an internal combustion engine according to the first aspect, wherein the exterior is manufactured by injection molding of plastic.

  Further, in claim 7, the control part for an internal combustion engine according to claim 1, wherein at least two or more are combined.

  Further, in claim 8, the control component is an internal combustion engine control component according to claim 7, which is an internal combustion engine igniter.

  According to a ninth aspect of the present invention, there is provided an igniter for driving an ignition coil disposed directly above an ignition plug for an internal combustion engine, wherein the ignition coil and the external connection terminal are formed integrally with the igniter exterior and disposed inside. In an igniter for an internal combustion engine ignition device in which an electronic component is molded with a mold resin, in the first molding stage, the external connection terminal is molded and restrained with the first molding resin to generate a first molded product. The electronic component is mounted on the molded product to generate the second molded product 140, and the second molded product 140 is inserted and molded with the second molding resin in the second molding stage. Control parts for internal combustion engines.

  According to a tenth aspect of the present invention, there is provided an igniter for driving an ignition coil disposed immediately above an ignition plug for an internal combustion engine, wherein the ignition coil and an external connection terminal are integrally formed with an igniter exterior and disposed inside. In an igniter for an internal combustion engine ignition device in which an electronic component or the like is molded with a mold resin, a first molding stage in which an external connection terminal is molded with a first molding resin, and an external connection terminal after the first molding stage The tie bar cutting process that cuts unnecessary parts of the tie bar, and after the molded product is inserted in the tie bar cutting process, the part that occupies most of the shape of the igniter exterior is made by injection molding of the second molding resin A control part for an internal combustion engine characterized by comprising the second molding stage.

  According to the configuration of the invention of claim 1, it is possible to manufacture the exterior of the control component for the internal combustion engine under ideal molding conditions without incurring an increase in the number of steps for manufacturing the control component for the internal combustion engine. It is possible to realize a control part for an internal combustion engine with high performance.

  According to the configuration of the invention according to claim 2, in the second molding stage, a small amount of the first molding resin fixing the external connection terminal and a portion occupying most of the exterior of the control part for the internal combustion engine are molded. Adhesion with the second molding resin is improved, and high insulation can be secured at the molding interface between the resins.

  According to the configuration of the third aspect of the invention, mechanical and physical characteristics as an exterior of the control part for an internal combustion engine are ensured, and peeling of the molding interface due to a difference in thermal expansion can be prevented.

  According to the configuration of the invention according to claim 4, the adhesion between the first molding resin and the second molding resin is improved, and high insulation can be secured at the molding interface between the resins.

  According to the configuration of the invention according to claim 5, the part molded in each stage so far is almost covered with the resin molded in the final molding stage, and the surface area of the part molded in the Nth molding stage. However, since it exceeds the surface area of the part molded in each stage so far, only the resin molded in the final molding stage can ensure the mechanical and physical characteristics as the exterior of the control parts for internal combustion engines. It is possible to mold under conditions adjusted to the above. Control parts for internal combustion engines having higher productivity and reliability can be provided at low cost.

  According to the configuration of the invention of claim 6, since the exterior of the control component for the internal combustion engine is manufactured by plastic injection molding, various exteriors of the control component for the internal combustion engine can be easily formed according to the performance. it can.

  According to the configuration of the invention according to claim 7, by combining at least two or more, a control part for an internal combustion engine having high productivity and reliability each having the effects and characteristics described in the previous section can be provided at low cost. I can do it.

  According to the configuration of the invention according to claim 8, the conventional sealing process of the tie bar cut hole is unnecessary, and the adhesion of the molding interface between the resins is maintained while maintaining the mechanical and physical characteristics as the igniter exterior. Strength can be improved, and an igniter having high productivity and reliability can be provided at low cost.

  According to the configuration of the invention according to claim 9, an igniter having high productivity and reliability in which an electronic component or the like is mounted and the electronic component is sealed by additional injection molding thereafter can be provided at low cost.

  According to the configuration of the invention according to claim 10, the conventional sealing process of the tie bar cut hole is unnecessary, and the adhesion strength of the molding interface between the resins is maintained while maintaining the mechanical and physical characteristics as the igniter exterior. It is possible to improve, and it is possible to provide an igniter having high productivity and reliability at low cost.

  Therefore, by adopting the technology of the present invention, it is possible to improve the adhesion of each molding resin in multicolor molding, to ensure the mechanical and physical characteristics of the exterior, and to prevent the separation of the molding interface due to the difference in thermal expansion. A control part for an internal combustion engine having high productivity and reliability can be provided.

  FIG. 1 shows a diagram of a second molded product representing Example 1 to which the technology of the present invention is applied. FIG. 2 shows a diagram of the first assembly representing the example to which the technology of the present invention is applied. The figure is shown in FIG. 3, the figure of the 2nd molded product showing Example 2 to which the technique of the present invention is applied is shown in FIG. 4, and the figure of the third assembly representing Example 2 to which the technique of the present invention is applied is shown. As shown in FIG. The igniter described below is defined as equivalent to that defined in the prior art. This will be described below with reference to examples.

  1 to 3, the igniter exterior 121 representing the first embodiment of the present invention is manufactured by plastic injection molding. As a first molding stage, first, the external connection terminal 122 to be inserted is first molded in a small amount. By molding with the resin 123, the external connection terminal 122 is fixed with the molding resin. This is referred to as a first assembly 131. Thereafter, an unnecessary portion of the external connection terminal 122 of the first assembly 131 is tie-bar cut, and this is used as a second assembly 132. Since the second assembly 132 is already fixed with the first molding resin 123, the external connection terminals 122 are not individually detached even after the tie bar cut.

  Thereafter, as a second molding step, after the second assembly 132 is inserted, a portion occupying most of the shape of the igniter exterior 121 is produced by injection molding with the second molding resin 125. This is designated as a second molded product 140.

  Thus, in the igniter showing Example 1 of the present invention, by inserting the second assembly 132, it is not necessary to seal the tie bar cut hole 24 in the post-process as in the prior art, the work is reversed, It becomes possible to reduce man-hours such as introduction of resin such as epoxy, curing, and introduction of a drying process.

  In addition, if the first molding resin 123 is molded using a low crystallization type that has a small dimensional change after molding and suppresses crystallization of the surface, the surface of the first molding resin 123 is formed in the second molding stage. By melting, the adhesiveness with the second molding resin 125 that molds the portion of the igniter exterior 121 is improved, and high insulation can be secured at the molding interface between the resins.

  Furthermore, the second molding resin 125 may be selected from those having a linear expansion coefficient approximate to that of the first molding resin 123. In this case, if it is assumed that the first molding resin 123 is a low crystallization type, the mechanical and physical characteristics as the igniter exterior 121 are ensured, and the molding interface is peeled off due to the difference in thermal expansion. Can be prevented. For example, the product name “Valox507” (linear expansion coefficient: 30 ppm / ° C.) manufactured by SABIC Innovative Plastics as the first molding resin 123, and the product name “ValoxVIC4311” manufactured by SABIC Innovative Plastics as the second molding resin 125 (line) This is achieved by using an expansion coefficient of 30 ppm / ° C.

  Furthermore, if it is assumed that the first molding resin 123 is a low crystallization type, it is preferable that the first molding resin 123 has irregularities on the outer peripheral surface thereof. For example, the mold of the first molding resin 123 has a rough surface, so that the adhesion between the first molding resin 123 and the second molding resin 125 is improved, and high insulation is provided at the molding interface between the resins. It can be secured.

  Furthermore, when the portion (second molded product 140) occupying most of the shape of the igniter exterior 121 is molded, the surface area of the portion molded in the second molding stage is the portion molded in the first molding stage. It is good to shape | mold so that the surface area of this may be exceeded. Thus, the first molding resin 123 is almost covered with the second molding resin 125, and only the resin molded in the second molding stage is ensured to have mechanical and physical characteristics as the igniter exterior 121. Molding under adjusted conditions is possible.

  In the first embodiment, the igniter exterior 121 of the ignition device for the internal combustion engine that is injection-molded by the two-color molding of the first molding stage and the second molding stage has been described, but also in a multi-stage molding stage such as multicolor molding. The present invention can be applied to each molding stage from the previous molding stage to the next molding stage every time the first molding stage to the final molding stage are sequentially followed.

  Resin characteristics, resin outer peripheral surface shape, resin linear expansion coefficient, resin melting energy, mold temperature and resin temperature to be molded, surface area of the molded part at each stage and the part to be molded at the final molding stage The relationship between the surface areas can be considered in the same manner as in the two-color molding of the first molding stage and the second molding stage. If the igniter exterior in the final molding stage is molded so as to ensure mechanical and physical properties, the molding is divided into N times (N ≧ 2) as a multi-stage molding stage such as multicolor molding. In the stage, n is nεN and is an arbitrary natural number, and can be applied to the characteristics and relationship of the resin in the (n−1) -th molding stage of the previous molding stage and the resin in the n-th molding stage of the next molding stage. As a result, the same effect can be obtained in each molding stage from the previous molding stage to the next molding stage. Therefore, the present invention can be applied not only in the two-color molding of the first molding stage and the second molding stage but also in each molding stage from the previous molding stage to the next molding stage of a multi-stage molding stage such as multi-color molding.

  Therefore, when the igniter exterior 121 of the present invention is produced by injection molding in a multi-stage molding stage such as multi-color molding, the second assembly 132 fixed with a small amount of molding resin and pre-cut with a tie bar is inserted. Then, when molding a portion (second molded product 140) occupying most of the shape of the igniter exterior 121, an optimal molding resin is selected at each stage, so that the conventional conventional tie bar cut hole 24 can be sealed. It is possible to improve the adhesion strength at the molding interface between resins while maintaining the mechanical and physical characteristics of the igniter exterior 121 without the need for a stopping process, and provide an igniter with high productivity and reliability at a low cost. I can do it.

  4 to 5, the igniter exterior 121 representing the second embodiment of the present invention is manufactured by plastic injection molding. As a first molding stage, external connection terminals 122 having terminals 122a and 122b are provided. Restrained with the first molding resin 123 and molded. This is the first assembly 131. Thereafter, an unnecessary portion of the external connection terminal 122 of the first assembly 131 is cut by a tie bar, and this is used as the second assembly 132. Thereafter, an electronic component 126 such as a chip resistor or driver IC for controlling the igniter or an ion current control IC for increasing the added value of the igniter is connected and mounted between the terminals 122a and 122b of the second assembly 132. Assen 133 is generated. Further, in the second molding stage, the third assembly 133 is inserted, and injection molding is performed with the second molding resin 125, whereby a portion (second molded product 140) occupying most of the shape of the igniter exterior 121 is produced. The

  In Embodiment 2, the electronic component 126 can be protected by covering the third assembly 133 on which the electronic component 126 is mounted with the second molding resin 125. Although not shown, an electronic component 126, an electronic component, and the like are further mounted on a portion (second molded product 140) that occupies most of the shape of the igniter exterior 121 manufactured in the second molding stage, and then additional injection is performed. The igniter may be configured by sealing by molding. Even in the second embodiment, the first molding stage and the second molding stage are the same molding stage as in the first embodiment described above, so that the mechanical and physical characteristics as the igniter exterior 121 are maintained, The adhesion strength of the molding interface between the resins can be improved, and an igniter having high productivity and reliability can be provided at a low cost.

  In Examples 1 and 2 of the present invention, the igniter exterior 121 is produced by plastic injection molding, but the molding method is not limited to injection molding. An igniter for driving an ignition coil disposed directly above an ignition plug for an internal combustion engine, wherein the ignition coil and the external connection terminal 122 are formed integrally with the igniter exterior 121, and an electronic component or the like disposed inside is formed. In the igniter of the internal combustion engine ignition device molded with the mold resin, any method can be applied as long as the molding method can form the resin as the igniter exterior 121. Further, the igniter exterior 121 is not limited to plastic, and it is possible to improve the adhesion strength of the molding interface between resins while maintaining the mechanical and physical characteristics as the igniter exterior 121, and has high productivity and reliability. Other thermoplastic resins can be applied as long as the igniter can be provided at low cost.

  Moreover, although Example 1, 2 demonstrated the igniter of the ignition coil for internal combustion engines, this invention is not limited to this. Ignition system for internal combustion engines that integrates electronic components such as IC chips, resistors, and capacitors typified by hybrid ICs that perform ion current control and ignition control on the same substrate, and engines that do not require ignition systems It can be applied to any control component for an internal combustion engine that is used in an environment that is exposed to thermal stress caused by starting and stopping of the internal combustion engine and that processes engine control, driving vehicle control, and other signal information. Needless to say. By applying the technology of the present invention to a control part for an internal combustion engine, the exterior formed by multicolor molding and the parts arranged inside are ensured sufficient adhesion, mechanical and physical characteristics, and It is possible to provide a control part for an internal combustion engine that can prevent peeling of the molding interface due to a difference in thermal expansion and has high productivity and reliability.

  The present invention has been described above based on the embodiments. However, the embodiment of the present invention is not limited to the above-described embodiments, and is based on the spirit of the present invention and is the same as the wording of the claims of the present invention. It is also possible to carry out various modifications and improvements that can be made by a trader.

It is a figure of the 2nd molded product showing Example 1 to which the technique of the present invention is applied. It is a figure of the 1st assembly showing the example to which the art of the present invention is applied. It is a figure of the 2nd Assen. It is a figure of the 2nd molded product showing Example 2 to which the technique of the present invention is applied. It is a figure of the 3rd assembly showing Example 2 to which technology of the present invention is applied. It is a longitudinal cross-sectional view of the ignition coil for internal combustion engines by a prior art. It is a figure of the igniter exterior by a prior art. It is a figure of the 1st shaping | molding step of the igniter exterior to which the conventional technique is applied.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Ignition coil 11 Core 12 Primary coil 13 Secondary coil 14 Cylindrical case 20 Igniter 21, 121 Igniter exterior 22, 122 External connection terminal 23 Molding resin 24 Tie bar cut hole 25 Epoxy resin 122a, 122b Terminal 123 First molding resin 125 Second molded resin 126 Electronic component 130 First molded product 131 First assembly 132 Second assembly 132 Third assembly 140 Second molded product

Claims (10)

  In a control part for an internal combustion engine in which an external connection terminal is formed integrally with an exterior, and an electronic component disposed inside is molded with a mold resin, the exterior is divided into a plurality of times from the first molding stage. A control part for an internal combustion engine characterized by being manufactured by performing.   The molding step divided into a plurality of times is N times (N ≧ 2), n is an arbitrary natural number of n∈N, and the resin in the n−1 molding step is lower than the resin in the nth molding step. 2. The control part for an internal combustion engine according to claim 1, wherein the control part is a crystallization type.   The molding step divided into a plurality of times is N times (N ≧ 2), n is an arbitrary natural number of n∈N, and the resin in the n−1 molding step and the resin in the nth molding step are linear 3. The control component for an internal combustion engine according to claim 2, wherein the expansion coefficient is approximate.   The molding step divided into a plurality of times is N times (N ≧ 2), n is an arbitrary natural number of n∈N, and the resin in the (n-1) th molding step has irregularities formed on the outer peripheral surface. The control part for an internal combustion engine according to claim 1, wherein:   The molding step divided into multiple times is N times (N ≧ 2). The part molded in each of the previous stages is covered with the part molded in the Nth molding stage and molded in the Nth molding stage. 2. The control part for an internal combustion engine according to claim 1, wherein the surface area of the portion to be formed exceeds the surface area of the portion formed in each of the steps so far.   The control part for an internal combustion engine according to claim 1, wherein the exterior is manufactured by plastic injection molding.   The control part for an internal combustion engine according to any one of claims 1 to 6, wherein at least two or more are combined.   In a control part for an internal combustion engine of an ignition device for an internal combustion engine in which an external connection terminal is formed integrally with an internal control part exterior for an internal combustion engine and an electronic component disposed inside is molded with a mold resin. The external connection terminal is molded and restrained with the first molding resin to generate the first molding, the electronic component is mounted on the first molding to generate the second molding, and in the second molding stage, The control part for an internal combustion engine according to claim 7, wherein the second molded product is inserted and molded with a second molding resin.   In an internal combustion engine control part of an ignition device for an internal combustion engine in which an external connection terminal is formed integrally with an internal control part exterior for an internal combustion engine and an electronic component disposed inside is molded with a mold resin, the external connection terminal is A first molding step molded with a first molding resin; and after the first molding step, a tie bar cutting step of cutting an unnecessary portion of the external connection terminal and a molded product molded by the tie bar cutting step 8. A second molding step in which a portion occupying most of the shape of the control component exterior for an internal combustion engine is inserted into the second molding step by injection molding of a second molding resin. The control part for internal combustion engines as described.   The control part for an internal combustion engine according to claim 8, wherein the control part is an igniter for an ignition coil for the internal combustion engine.

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