JP4986238B2 - Manufacturing method of injection molded body - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the occurrence of a gap between a vehicle B and a side winker 1 in manufacturing the side winker 1 by mutually abutting a lens part 2 and a housing 4 both of which are molded by primary injection and subsequently secondarily injecting a resin material 5 to integrate the lens part 2 and the housing 4. <P>SOLUTION: After a third mold Z is operated so as to be retracted in a state of integration by secondary injection to form a space S, an elastic resin material 7 serving as a packing is thirdly injected in the space S. By this method, the packing can be simply integrated with the side winker 1 without being positionally shifted to eliminate the gap with respect to the vehicle B. <P>COPYRIGHT: (C)2008,JPO&amp;INPIT

Description

The present invention belongs to the technical field of manufacturing how the hollow lamp Representative is Ru y de molding of the side turn signal or the like attached to the vehicle body.

In general, when manufacturing this kind of hollow injection molded body, when this is a side winker, after the primary injection of the lens part formed of a translucent material and the housing in which the bulb (light source) is incorporated, It is known that a lens side and a housing are abutted by moving a mold, and a secondary side injection is performed on the abutting part to integrate them to manufacture a hollow side blinker.
By the way, in this, a lens portion and a housing are formed with a corner-shaped injection space at a butting portion, and a resin material is secondarily injected therein to be integrated (for example, Patent Document 1). .
JP 2002-113743 A

  However, when the product manufactured by the above method is incorporated in the vehicle body as it is, the secondary injection part is incorporated in a state of directly facing the vehicle body. When facing each other, there is a problem that the gap becomes large and a wind noise is generated, which causes noise, and further, water such as rain enters from the gap, and this enters the inside of the vehicle body. There was a problem such as. Therefore, it is proposed that an elastic packing is affixed to the back surface of the side blinker so that a gap is not opened between the opposing surfaces. However, the affixing operation of the packing is cumbersome and complicated, and the workability is inferior. In addition, there is a problem that a deviation occurs in the sticking position and product variation occurs, and there is a problem to be solved by the present invention.

The present invention was created with the object of solving these problems in view of the above-mentioned circumstances, and the invention of claim 1 matches the first and second semi-finished products. When the resin material is injected into the mating part and integrated, and the resin material is further injected onto the outer surface of the integrated material and molded , the integration of the first and second semi-finished products is the integration of the first semi-finished product. After being molded by the primary injection process, the first semi-finished product is butted with the second semi-finished product formed in a process different from the first semi-finished product, and then a resin material is put on the butted portion. In what is integrated by secondary injection, after the integration, by third injection into the space formed by moving the mold provided with the mold surface for forming the integrated part, and characterized in that the injection of the resin material on the outer surface of the integrated site That is a method for producing an injection molded article.
A second aspect of the present invention, the resin material region which is injected into the outer surface is a method of manufacturing an injection molded article of claim 1 Symbol mounting, characterized in that a back surface of the resin region is injected into the butt portion.
A third aspect of the present invention, the resin material is injected into the outer surface of claim 1 or 2 injection-molded body according to characterized in that having a projecting piece which projects radially outwardly of the injection molded article It is a manufacturing method.
The invention according to claim 4 is the method of manufacturing an injection-molded article according to any one of claims 1 to 3 , wherein the resin material injected to the outer surface has elasticity.

According to the invention of claim 1, a resin material that can be used as a packing can be easily formed on the outer surface of the integrated injection-molded body by injection without misalignment. Not only can the compact be mass-produced in a high-quality state without variation, but also a series of primary injection, secondary injection, and tertiary injection using a second semi-product produced separately. Thus, an injection molded body in which the resin material is injected on the outer surface can be produced.
According to the invention of claim 2 , the resin material is injected on the outer surface using the resin material region injected to integrate the semi-finished products.
According to the invention of claim 3, the protruding piece formed on the resin material injected to the outer surface is incorporated in a state in which the injection molded body protrudes, thereby improving the function of the resin material as a packing.
By setting it as invention of Claim 4, the resin material inject | emitted on an outer surface has elasticity, and noise generation and wind noise generation can be reduced more reliably.

Next, a first reference example of the present invention will be described with reference to the drawings. In the drawings, reference numeral 1 denotes a side blinker (lamp). The side blinker 1 includes a lens unit 2 and a lamp body (a light source may be used, for example, a light bulb or a light emitting diode can be used). 3 and the housing 4 in which the lens unit 2 and the housing 4 are formed as a primary injection product which is a half product, each of which is a fixed mold and a movable mold, and then the movable mold is slid to move both primary parts. After the injection products are butted together, as will be described later, the resin material 5 for integration is secondarily injected to the butted face portion and molded integrally by a conventionally known technique. Since is described in detail in the above-mentioned Patent Document 1, etc., the description thereof is omitted. It should be noted that the present invention can also be implemented by forming a reflective film on the inner surface of the housing after the primary injection and then integrating it by secondary injection.

  The lens portion 2 formed by the primary injection molding has a bowl shape, and a horizontal first end surface portion 2a is formed at an opening edge that faces in the front-rear direction. A stepped surface portion 2b projecting stepwise from the outer peripheral edge of the surface portion 2a toward the housing 4 side, and a second end surface portion 2d extending in a horizontal manner from the leading edge of the stepped surface portion 2b and continuing to the outer peripheral surface 2c of the lens portion 2 are sequentially formed. Is formed. Further, a taper surface portion (first taper portion) 2f is formed on the inner side of the first end surface portion 2a. The taper surface portion (first taper portion) 2f is inclined toward the center toward the bottom of the lens portion in a state following the lens portion inner peripheral surface 2e. ing. In addition, a fitting recess 2h is formed in a groove shape on the inner diameter side (tapered surface portion 2f side) of the first end face portion 2a so as to fit a fitting protrusion 4e described later formed on the housing 4 side. ing. Incidentally, the material which comprises the lens part 2 is polymethylmethacrylate resin which permeate | transmits light.

  On the other hand, the housing 4 formed by primary injection molding includes a socket portion 4a to which the lamp body 3 and the terminal plate 3a are attached, and a flange projecting in a horizontal (left-right) flange shape from the outer peripheral edge of the base portion of the socket portion 4a. The edge portion of the flange portion 4b is formed in a state of being separated from the fitting convex portion 4e fitted to the lens portion fitting concave portion 2h and the lens portion step surface portion 2b. An outer end surface portion 4d serving as an outer peripheral end surface of the fitting convex portion 4e is formed. Further, on the outer peripheral edge of the flange portion 4b, a tapered surface portion (second tapered portion) 4f that is inclined so as to face the tapered surface portion 2f is formed on the inner diameter side of the fitting convex portion 4e. . Incidentally, the material of the housing 4 is a polycarbonate (PC) resin.

The side blinker 1 makes the lens part 2 and the housing 4 injection-molded as the primary product face to face each other by a known mold moving method. At this time, the housing fitting convex part 4e is the lens part. The taper surface portions 2f and 4f are brought into contact with each other in the fitting recess 2h, and in this abutting state, the resin material 5 for integration is further injected secondarily to form the body of the side blinker 1. However, the resin material 5 is injected into a band-like space formed by a mold on the abutting surface portion between the back surface 4g of the flange portion 4b and the lens portion outer peripheral surface 2c, whereby the resin material 5 is injected into the first end surface portion 2a. Setting that is built up so as to adhere to the outer side of the housing side outer end surface part 4d, the step surface part 2b, the second end surface part 2d, and the housing side outer end face part 4d. In this case, the lens portion 2 as the primary injection product and the housing 4 are brought into contact with each other at the corner portion which is substantially L-shaped when the side blinker 1 as the secondary injection product is formed. It is set to be. Incidentally, in the first reference example , the resin material 5 that is secondarily injected uses the same polymethyl methacrylate resin as the lens portion 2 in color and material, but is the same in color and material as the housing 4. Polymethyl methacrylate (PMMA) resin may be adopted.

Next, a tertiary injection is performed on the side blinker 1 after the secondary injection to form an elastic packing. The resin material 7 injected by the tertiary injection is set so as to adhere to the back surface 5a of the resin material 5 to be secondary injected. Incidentally, in the first reference example , the resin material 7 to be thirdarily injected can employ an elastomer that is a rubber-like elastic body or a resin material such as soft acrylic. In this case, the resin material is The material is not limited to the actual material, and may be a foam material.

  Further, in this case, the side blinker 1 has an elliptical shape, and the housing 4 is fitted and incorporated in the mounting hole 6 drilled in the vehicle body B. A locking protrusion 4n having a locking recess 4h for locking to the mounting hole 6 is formed on the side, and a locking leg 4i having elasticity is formed on the other side. The side winker 1 is forcibly fitted into the mounting hole 6 so that the locking leg 4i is elastically deformed toward the center side, and the locking leg 4i is moved when the locking groove 4h reaches the hole edge of the mounting hole 6. By partially returning elastically, the inner peripheral edge of the mounting hole 6 is fitted into the locking groove 4h, so that simple elastic mounting can be performed. At this time, the side blinker 1 and the vehicle body B are brought into close contact with each other by the resin material 6 injected by the third injection.

Next, the mold alignment state based on a known mold moving method when performing primary injection and secondary injection will be described in detail with reference to the drawings. When X is set as the first mold that is the fixed side, and Y is set as the second mold that is the movable side, the mold-matching state at the time of the primary injection is first, but on the lens unit 2 side shown in FIG. The first mold X includes a lens portion inner peripheral surface 2e, a tapered surface portion 2f, a fitting recess 2h, a first end surface portion (contact horizontal surface portion) 2a, a step surface portion (projection surface portion) 2b, and a second end surface portion (protrusion). A mold surface corresponding to each surface such as (horizontal surface portion) 2d is formed. On the other hand, a mold surface such as a mold surface Ya, which is a mold surface corresponding to the lens outer peripheral surface 2c, is formed on the second mold Y.
On the other hand, on the housing 4 side shown in FIG. 4, the first mold X has a back surface 4g of the flange portion 4b and a surface corresponding to the flange back surface 4g, that is, an injection region of the resin material 5 to be secondarily injected. A mold surface Xa that is flat with the back surface 5a, and an outer surface of the injection region of the resin material 5, that is, a mold surface such as the mold surface Xa and the mold surface Xb that is substantially L-shaped. In addition, in the mold surface portion corresponding to the back surface 5a of the injection region of the resin material 5 of the first mold X, a third mold Z which is a movable mold described later is flat with the mold surface Xa of the first mold. In this state, that is, the mold surface Za corresponding to the back surface 5a of the injection region of the resin material 5 is formed. On the other hand, the mold surface corresponding to the outer end surface portion 4d of the flange portion 4b, the surface of the fitting convex portion 4e, the tapered surface portion 4f, and the like is formed on the second mold Y. The primary injection is executed in this mold matching state, and the lens portion 2 and the housing 4 are molded as a primary product.

  When the primary injection molding is executed, the first mold X is removed from the lens portion 2 side, and the secondary mold Y is removed from the housing 4 side. Next, the mold is moved so that the lens portion 2 and the housing 4 face each other, and the lens is fitted by fitting the lens portion fitting concave portion 2h and the housing fitting convex portion 4e. Then, the resin material 5 is secondarily injected in this mold-matching state. In this secondary injection region, the mold surface Ya serving as the outer surface of the secondary injection region of the second mold Y is the lens outer peripheral surface 2c. And the projecting horizontal surface portion 2d are set to be recessed with respect to the corner portion 2g. In this state, the secondary injection is performed. Even if it penetrates into the gap between the mold Y and the lens part 2, it can be prevented from reaching the lens part surface 2c beyond the corner part 2g by stopping at the corner part 2g at most. It has become.

  In this way, secondary injection is performed, and after the lens portion 2 and the housing 4 are integrally formed as the side blinker 1, the resin material 7 for forming packing on the back surface of the resin material 5 for integration is subjected to tertiary injection. The tertiary injection process will be described in detail below. First, as described above, when the secondary injection is performed, the third mold Z, which is a movable mold incorporated in the first mold X, retreats by the thickness of the packing formed by the tertiary injection. As a result, the space S for the third injection is formed between the back surface 5a of the resin material 5 and the mold surface Za of the third mold Z. Then, the packing is formed by third-injecting the resin material 7 into the space S. At this time, the width of the horizontal plane of the space S, that is, the width of the mold surface Za of the third mold is smaller than the width of the resin material 5 of the secondary injection, and the outer surface of the tertiary injection resin material 7 is 2 The inner surface of the tertiary injection resin material 7 is set to be recessed with respect to the outer surface of the secondary injection resin material 5 with respect to the inner surface of the secondary injection resin material 5. Thereby, the resin material 7 subjected to the third injection is adhered only to the back surface 5a portion of the secondary injection resin material 5 without entering the outer surface of the secondary injection resin material 5 or the outer peripheral surface 2c of the lens portion. .

In the first reference example configured as described above, the manufactured side blinker 1 is injected into the vehicle body B by injecting a tertiary injection resin material (packing) 7 on the back surface 5a of the resin material 5 that has been secondary injection. When assembled, there is no gap due to curvature or unevenness generated in the vehicle body B or the side blinker 1, so that both can be attached in close pressure, wind noise during running, water such as rain, etc. Can be prevented. Furthermore, since it is necessary to adjust the thickness of the tertiary injection resin material 7 depending on the magnitude of the downward movement of the third mold Z, the thickness of the packing depends on the material of the resin material 7 and the characteristics of the product (lamp). It is easy to change the thickness, and if the third mold Z is not moved downward, a product without packing can be made. For example, a flexible response can be easily made.

The present invention may also be as a second reference example shown in FIG. 8-12. In the second reference example , the tertiary injection resin material 7 is injection-molded as having a protruding piece protruding in the outer diameter direction of the side winker 1. The details will be described below.
For primary injection, the same mold as the first reference example can be used on the lens unit 2 side. On the other hand, as shown in FIG. 8, on the housing 4 side, the first mold X has a third mold Z, which is a movable mold, as in the first reference example. It is assembled in a state flat with the surface Xa, that is, in a state where a mold surface Za corresponding to the back surface 5a of the injection region of the resin material 5 is formed. The third mold Z has the projecting piece 7a on the packing. A corner portion Zb for forming is formed. The corner portion Zb is provided so as to protrude in the outer diameter direction from the outer surface of the secondary injection resin material 5, that is, to protrude outward from the mold surface Xb of the first mold X. Yes. On the other hand, the mold surface similar to the first reference example is formed on the second mold Y. Then, primary injection is performed in this mold-matching state, and the lens part 2 and the housing 4 are molded as a primary product. Further, as shown in FIG. 9, the lens part 2 and the housing 4 are mold-matched. The resin material 5 is secondarily injected in the mold matching state.

  In this way, secondary injection is performed, and after the lens portion 2 and the housing 4 are integrally formed as the side blinker 1, tertiary injection for forming packing on the back surface 5a of the resin material 5 is performed. At this time, since the corner part Zb for forming the projecting piece is formed in the third mold Z, a space having a space for forming the projecting piece when the third mold Z moves downward. S is formed. And the packing which has the protrusion 7a which protrudes in an outer-diameter direction is formed by carrying out the tertiary injection of the resin material 7 to this space S. FIG.

  In such a configuration, by incorporating the side blinker 1 having the projecting piece 7a in the packing into the vehicle body B, a step generated between the side blinker 1 and the vehicle body B becomes gentle, and wind noise is generated. Can be suppressed. Further, when the side blinker 1 is assembled into the vehicle body B, the projecting piece 7 a is pressed by the vehicle body B and is elastically biased, so that the packing joins the secondary injection resin material 5 and the tertiary injection resin material 7. The part and the part to be assembled with the vehicle body B are concealed, and the visibility can be improved even when the side blinker 1 is incorporated into the vehicle body B.

The primary molding of the lens portion 2 and the housing 4 is not limited to the case where the lens portion 2 and the housing 4 are molded by the same primary injection process as in the first and second reference examples. What is molded by different injection processes for at least one of the portion 2 and the housing 4 may be integrated, and a resin material may be further injected and molded on the outer surface of the integrated one . A reference example will be described.

13 to 14 that of the first implementation embodiment are shown in the lens unit 2 and the housing 4 and the leave the primary injection molding in a separate step, mutually butt the those such by molding After the lamp body is integrated with the butting portion by a secondary injection step, the resin material 7 is further injected into the outer surface of the lamp body, and in this case, the first material shown in FIG. As in the embodiment, after the lens portion 2 and the housing 4 molded in different primary injection processes are assembled in the molds X and Y, the resin material 5 is secondarily injected and integrated, and then the mold after forming the injection space S by mold moving Z, but it may also the resin material 7 and tertiary injection into the space S. Further, as in the third reference example shown in FIG. 15, after the lamp body 1 integrated in advance by primary injection and secondary injection is incorporated in the molds X and Y, the resin material 7 is tertiary injected. In this case, a space S for tertiary injection of the resin material 7 may be formed in the mold X in advance.

  Further, the resin material 7 to be thirdarily injected is not limited to the resin material 5 portion to be secondarily injected as described above, but may be the outer surface of the lens unit 2 as shown in FIG. 16 (B) and (C) can be used as the back surface or the front surface of the housing portion 4, and as shown in FIG. 16 (D), the outer surface from the secondary injection resin material 5 to the housing portion 4 can be formed. Or an outer surface from the secondary injection resin material 5 to the lens portion 2 as shown in FIG. 16 (E), and further from the secondary injection resin material 5 to the lens portion 2 and the housing as shown in FIG. 16 (F). Or an outer surface that reaches the portion 4.

It is a side view of a side blinker. It is a cross-sectional view of a side blinker. It is a fragmentary end view showing the primary injection process of the lens part of the first reference example . It is a fragmentary end view showing the primary injection process of the housing of the 1st reference example . It is a partial end elevation showing the secondary injection process of the 1st reference example . It is a partial end elevation showing the tertiary injection process of the first reference example . It is a partial expanded sectional view of the injection molded product after the third injection of the first reference example . It is a fragmentary end view showing the primary injection process of the housing which shows the 2nd reference example . It is a partial end elevation showing the secondary injection process of the 2nd reference example . It is a partial end elevation showing the tertiary injection process of the 2nd reference example . It is an expanded partial sectional view of the side blinker which shows the 2nd reference example . It is sectional drawing which shows the state which attached the side blinker which shows a 2nd reference example to the vehicle body. It is a general | schematic process figure which shows 1st embodiment . It is the fragmentary end view which showed the secondary and tertiary injection | emission process of 1st embodiment . It is the fragmentary end view which showed the tertiary injection process of the 3rd reference example . (A)-(F) is a fragmentary sectional view which shows the form of a deformation | transformation of the resin material inject | emitted tertiary.

Explanation of symbols

2 Lens portion 2c Lens outer peripheral surface 2g Opening edge 2h Fitting recess 4 Housing 4e Fitting protrusion 5 Secondary injected resin material 7 Tertiary injected resin material (packing)
10 Side blinker S space

Claims (4)

In matching the first and second semi-finished products, injecting and integrating a resin material to the abutting part, and further injecting the resin material on the outer surface of the integrated, and molding ,
The integration of the first and second semi-finished products is that the first semi-finished product is formed by a primary injection process, and then formed into the first semi-finished product in a process separate from the first semi-finished product. The second semi-finished product is abutted, and then a resin material is secondarily injected into the abutting portion and integrated, and after the integration, a mold surface for forming the integrated portion is provided. A method of manufacturing an injection-molded article, characterized in that a resin material is injected onto the outer surface of the integrated part by performing a third injection into a space formed by moving the formed mold. Resin material region which is injected into the outer surface, the production method of the injection molded article of claim 1 Symbol mounting, characterized in that a back surface of the resin region is injected into the butt portion. 3. The method of manufacturing an injection molded body according to claim 1, wherein the resin material injected to the outer surface has a protruding piece protruding in the outer diameter direction of the injection molded body. The method for manufacturing an injection-molded article according to any one of claims 1 to 3 , wherein the resin material injected to the outer surface has elasticity.

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