JP5426143B2 - Manufacturing method of injection molded body - Google Patents

Description

  The present invention belongs to the technical field of an injection molded body manufacturing method typified by a side winker or the like attached to an automobile body or a door mirror.

In general, when manufacturing a hollow injection molded body of this type, when this is a side blinker, a lens portion formed of a translucent material and a housing in which a bulb (light source) is incorporated are each injection molded. After that, the lens unit and the butted surface of the housing are joined to form a united body, and as a method for joining such a lens unit and the butted portion of the housing, there is a method using ultrasonic fusion. It is known (see Patent Document 1).
Japanese Utility Model Publication No. 6-12564

  However, ultrasonic fusion is a method in which vibration is applied to the molded body to transmit vibration energy to the joining surface, and the vibration energy is converted into frictional heat to raise the resin at the joining portion to the melting point and weld it. If there are irregularities in the bonded portion or if dirt is adhered, unevenness may occur in the fusion, or a portion where the fusion is not sufficient may occur. When the fusion unevenness occurs, if the housing is molded with an opaque material and the lens part is molded with a transparent material, the molded product is molded with a transparent material. Through the lens portion, the fusion unevenness of the joint portion can be seen from the outside, which is not preferable in appearance. Also, if the fused part is peeled off due to inadequate fusion or deterioration over time, dirt or raindrops may infiltrate from this part, causing dirt to accumulate inside or condensation. These are the problems that the present invention does not solve.

The present invention has been created in view of the above-described circumstances and has been created for the purpose of solving these problems. The invention of claim 1 is a method of forming a half-shaped molded body between a plurality of molds. An injection molded body in which a plurality of molded bodies are molded in the first injection step, then the molded bodies are butted together and integrated in the second injection step of injecting a resin material onto the butted surfaces to produce a molded body body In the manufacturing method, a flow path is formed in the butt surface of at least one molded body molded in the first injection step, and the resin material is injected into the flow path in the second injection step . The flow path to be injected in the second injection step includes the periphery of the built-in component, and the embedded component is integrated with the molded body with the resin material injected in the second injection step . It is a manufacturing method.

According to the first aspect of the present invention, the half-shaped molded bodies injected in the first injection step can be reliably integrated by injection in the second injection step and connected to an external power source. As a result, it is possible to reliably incorporate the built-in parts such as the electronic member into the molded body, thereby preventing problems such as disconnection .

Next, embodiments of the present invention will be described with reference to the drawings.
In FIGS. 1A and 1B, reference numeral 1 denotes a body of a door mirror that is attached to each door on the driver's seat side and the passenger seat side of the vehicle, and a portion facing the rear (vehicle rear) of the body 1 An opening (not shown) is formed in the opening, and a mirror (not shown) for rearward confirmation is fitted into the opening so as to be adjustable in position. Further, the body 1 is rotatably supported by a stay 1a fixed to the door side, and an action posture in which the mirror can face rearward and can be confirmed by the driver, and on the door surface so that the mirror does not get in the way. It is comprised so that it may rotate and change into the storing attitude | position stored along.

The body 1 is swelled toward the front of the vehicle in the action posture of the door mirror, and is formed in a bowl shape with an opening at the rear, and the bulge 1b is provided for adjusting the mirror posture. Members and the like are accommodated. Further, an opening 1c is formed in a state where the body 1 is notched slightly below the center position of the body 1, and a side for instructing the opening 1c in the traveling direction (steering direction) of the vehicle. A blinker 2 is incorporated.
Here, the left and right symmetric door mirrors are provided on the left and right door bodies of the vehicle, respectively, but here, the door mirror provided on the left side of the vehicle shown in FIG. 1 will be described, and the right side door mirror will be omitted.
Incidentally, the side blinker 2 need not be limited to those attached to the door mirror as described above, and is attached to the left and right side surfaces of the vehicle body 1d as shown in FIGS. 2 (A) and 2 (B). Although there may be, this thing with a small protrusion amount from a vehicle main part is preferable. In this case, the side blinker 2 has an elliptical shape in a side view of the vehicle at the time of attachment, and bulges toward the outside of the vehicle in a plan view of the vehicle. In this device, as shown in FIG. 3 (A), a bulb (bulb) 5a as a light source is built in the central portion of the side blinker 2, and the power connection terminal 5c is assembled so as to face the vehicle longitudinal direction. However, the present invention is not limited to this, and it is of course possible to implement even if the power supply connection terminal 5c is assembled so as to face inward in the left-right direction of the vehicle as shown in FIG. it can.

  As shown in FIG. 4, the side blinker 2 includes an outer housing 3 housed inside the body 1, an outer lens 4 exposed to the outside (front) together with the outer peripheral surface of the body 1, and an inner surface ( An inner housing 5 in which a light source 5a and a substrate 5b connected to the light source 5a are integrally incorporated is provided on the front surface.

  The outer housing 3 is integrally formed by injecting a resin material, and has a long bowl shape in the left-right direction in which the vehicle front side opens in a curved shape from the front direction toward the left side. On the other hand, the outer lens 4 is formed in a bowl shape with an opening at the rear, and the outer housing 3 and the outer lens 4 are respectively molded in the first injection step (primary injection) step as will be described later. After that, the inner housing 5 is assembled into the outer housing 3, and then the opening end edges of the outer housing 3 and the outer lens 4 are butted together, and the resin material 6 is injected into the butted portion in the second injection step. It can be manufactured by injecting and integrating with (secondary injection).

  As shown in FIG. 5, the integrated side blinker 2 has a flow path of the resin material 6 on the abutting surface portion by abutment between the opening edge of the outer lens 4 and the opening edge of the outer housing 3. The resin material 6 is secondarily injected here, whereby the outer lens 4 and the outer housing 3 are integrally formed. At this time, the flange portions of the outer lens 4 and the outer housing 3 are abutted to each other to form a space portion 7, and the flow formed at the outer peripheral edge portions of the outer lens 4 and the outer housing 3 in this abutting state. The space portion 7 is sealed by secondary injection of a resin material into the path.

  In FIG. 6, reference numeral 8 denotes a first mold, and the first mold 8 includes a concave mold surface 8 a for forming the outer housing 3 and a convex mold surface for forming the outer lens 4 in the primary injection process. 8b. Reference numeral 9 denotes a second mold, and the second mold 9 is formed with a convex surface 9a for forming the outer housing 3 and a concave surface 9b for forming the outer lens 4 in the primary injection process. Has been.

Next, a first reference example of the manufacturing process of the side blinker 2 will be described.
First, as shown in FIG. 6A, in the first injection step, the concave surface 8a for forming the outer housing 3 of the first and second molds 8 and 9, the convex surfaces 9a and the outer lens 4 are formed. The first mold 8 and the second mold 8 are clamped together in a state where the convex surface 8b and the concave surface 9b are aligned with each other, and the primary injection is thereby performed, whereby the outer housing 3 and the outer lens 4 Are molded.

  Here, in the concave mold surface 8a for forming the outer housing 3 of the first mold 8, a flow path forming portion 8c is formed so that a flow path is formed adjacent to both ends of the outer housing 3 formed by primary injection. In addition, the flow path is formed at both ends of the convex surface 9a for forming the outer housing 3 of the second mold 9 so as to form a flow path of the resin material 6 injected in the secondary injection described later. A protrusion 9c that fits into the portion 8c is formed. In the primary injection step, the outer housing 3 is formed by primary injection with the projection 9c of the second mold fitted to the flow path forming portion 8c formed in the first mold 8.

Then, as shown in FIG. 6 (B), after the primary injection process is performed, the first and second molds 8 and 9 are separated from each other. The outer housing 3 is separated from the second mold 9 while the outer lens 4 is supported by the second mold 9 and the outer lens 4 is separated from the first mold 8. To do. At this time, the projecting portion 9c formed on the second mold 9 is also separated from the flow path forming portion 8c formed on the first mold 8, and in this state, the both ends of the outer housing 3 are separated. The flow path forming part 8c formed in the part opens in the second mold 9 direction.
In this case , the inner housing 5 which is a part is assembled. As a part assembling process, when the first and second molds 8 and 9 are released, the first mold is assembled. The inner housing 5 can be incorporated into the outer housing 3 supported by the mold 8, but can also be executed at the stage shown in FIG.

  Next, as shown in FIG. 6 (C), the first and second molds 8 and 9 are moved relative to each other in the direction along the mold surface in a separated state, and the concave mold surface 8a of the first mold 8 and After the concave mold surface 9b of the second mold 9 faces each other, as shown in FIG. 6D, when the first mold 8 and the second mold 9 are aligned with each other, The opening edge portions 3a and 4a of the outer housing 3 and the outer lens 4 formed in the primary injection process face each other. At this time, the flow path formed in the first mold 8 is formed. The portion 8 c is covered with the outer surface of the opening edge portion 3 a of the outer housing 3 and the lower surface of the opening edge portion 4 a of the outer lens 4 to form a flow path for the resin material 6. Then, the resin material 6 is secondarily injected into the flow path, whereby the outer housing 3 and the outer lens 4 are integrated, and the side blinker 2 is integrally formed. At the same time, the outer housing 3 and the outer lens 4 are integrated to form the hollow portion 7 in the molded body, and the inner housing 5 described above is attached to the hollow portion.

  When the film forming process for forming the film on the outer housing 3 is performed, the film forming process can be performed by inserting the film forming process between (C) and (D) of FIG. That is, in the film forming process, as shown in FIG. 7A, after the first mold 8 and the second mold 9 are separated from each other, the outer housing 3 in a state of being in contact with and supported by the second mold 9 is used. 7 (B) and 7 (C), a film forming apparatus represented by a vacuum evaporation apparatus for film forming processing by relative movement and mold matching of the second mold 9 with respect to the first mold 8. After the film is placed on the mold surface in which the film 10 is incorporated, a film forming process is performed in a state where the molds are aligned, and after the film forming process is performed, as shown in FIGS. The first mold 8 is moved away from the second mold 9 and moved relative to the second mold 9 again, and then moved to the secondary injection process.

In the first reference example configured as described above, after the primary injection of the outer housing 3 and the outer lens 4, the primary molded outer housing 3 and the outer lens 4 are abutted by mold matching, The side blinker 2 which is a hollow injection molded body is integrally formed by the secondary injection of the resin material 6 into the flow path formed in the abutting portion, and is halved by the secondary injection. While the outer housing 3 and the outer lens 4 are integrated to form the side winker 2 integrally, the flow path through which the resin material 6 that is secondarily injected flows is part of the main shape of the side winker 2. A beautiful injection-molded body having a high degree of completeness can be produced without any wasted parts.

Incidentally, in this reference example , the molded body is such that the hollow portion 7 is sealed by secondary injection, but is not limited to this, and a part of the hollow portion 7 as shown in FIG. May be configured to have an opening 7a.

Moreover, in this reference example , the flow path of the resin material 6 is matched with the outer housing 3 and the outer lens 4 which are the halves of the molded bodies that are abutted with each other, and the first mold 8 that is matched in the secondary injection process. In this case, the resin material 6 is injected here. For example, as shown in FIG. In these cases, as shown in FIGS. 8C and 8D, the flow path of the resin material 6 may be formed so as to extend between both halves. Of course, these various flow paths may be partially combined.

The material and color of the resin material 6 to be secondarily injected are not particularly limited, and may be the same material as any of the half of the molded body, or may be a different material.
Further, the resin material 6 may be a soft resin material typified by polypropylene, and by using such a soft resin material, as a packing or a vibration isolating material when the injection molded body is attached to the housing. Further, when the internal pressure in the hollow portion of the injection molded body changes due to a temperature change or the like, it can be configured to absorb the change in internal pressure by expanding and contracting.

Furthermore, as in the reference example of the second side blinker shown in FIG. 9A, a tapered surface 4b that is inclined toward the abutting surface with the outer housing 3 is formed on the edge of the outer lens 4, The first end surface portion 4c that is horizontal from the tapered surface 4b toward the outer peripheral edge of the outer lens, the step surface portion 4d that protrudes in a step shape from the outer peripheral edge of the first end surface portion 4c toward the housing, and the step surface portion A second end face portion 4f is formed horizontally from the outer edge 4e of the outer lens 4 horizontally from the tip edge of 4d, while the end face portion of the outer housing 3 faces the tapered surface 4b of the outer lens 4 at the time of butting. The tapered surface portion 3a that contacts, the contact horizontal surface 3b that extends horizontally from the edge portion of the tapered surface portion 3a and makes surface contact with the first end surface portion 4c, and the direction away from the outer lens 4 from the edge portion of the contact horizontal surface 3b. It is assumed that the formation of the outer end face portion 3c became Sajo. And in this thing, in the abutting of the outer lens 4 and the outer housing 3, the taper surface 4b formed in the outer lens 4, the first end surface portion 4c, the taper surface portion 3a formed in the outer housing 3, and the contact horizontal surface 3b In this state, the resin material 6 is secondarily injected into the flow path forming portion 8c to form the side blinker 2. In this way, the resin material that is secondarily injected is formed. It can prevent that 6 leaks in a hollow part.

Furthermore, as in the third reference example shown in FIG. 9B, a fitting convex portion 4g and a fitting concave portion 4h are formed in order from the outer lens central side surface of the first end surface portion 4c formed on the outer lens 4. On the other hand, a fitting concave portion 3d and a fitting convex portion 3e are formed between the tapered surface portion 3a and the first end surface portion 3c of the outer housing 3, and the fitting convex portion is brought into contact with the outer lens 4 and the outer housing 3. 4g, the fitting concave portion 4h, the fitting concave portion 3d, and the fitting convex portion 3e are fitted to each other, and in this state, the resin material 6 is secondarily injected into the flow path forming portion 8c and injection molded. Even if it does in this way, it can prevent that the resin material 6 which carries out secondary injection leaks in a hollow part.

  With such a configuration, when the resin material 6 is secondarily injected at the abutting portion between the outer lens 4 and the outer housing 3, the outer lens 4 and the outer housing 3 receive the injection pressure in the left-right direction and the vertical direction. However, as described above, since the contact surface between the outer lens 4 and the outer housing 3 receives the injection pressure in a state of being abutted by surface contact in two directions, the injection pressure is more reliably received. In particular, in the case of secondary injection in a state where the fitting recess 3d and the fitting protrusion 3e of the outer housing 3 are fitted to the fitting protrusion 4g and the fitting recess 4h of the outer lens 4, the taper is tapered. Since the injection pressure is received at the part where the surface and the uneven fitting part are in close contact, the injection pressure can be received more reliably, and the secondary Resin material 6 that is can be prevented from leaking to the burr shape in the gap into the space section 7.

The present invention will be described in the embodiment shown in FIGS. As shown in FIG. 10, the base 11a of the coupler 11 provided so as to protrude outward from the side winker 2 for supplying power to the light source 5a is integrated with the side winker 2 in accordance with the secondary injection. It is fixed.

  In other words, as shown in FIGS. 11A, 11B, and 11C, this is provided at one end of the outer peripheral edge portion 3d formed on the outer housing 3 from the outer housing outer peripheral edge portion 3d toward the outside. A coupler support portion 3e for fitting and supporting the flange-like base portion 11a of the coupler 11 from the outer lens 4 side is provided so as to protrude outward from the outer peripheral edge portion. Is formed with a stepped portion 3f that is recessed with respect to the mold so as to surround the coupler base 11a as a flow path of the resin material 6 to be secondarily injected between the coupler base 11a that is fitted and supported. . Further, the outer lens 4 has a coupler support portion 4j that protrudes from the coupler support portion 3e so as to cover the coupler support portion 3e and to contact and support the coupler base portion 11a. The coupler support portion 3e is formed with a groove portion 3g for forming a flow path of the resin material 6 that is secondarily injected to the butting surface portion with the coupler support portion 4j on the outer lens 4 side in a state of communicating with the step portion 3f. ing.

  When the outer lens 4 is abutted against the outer housing 3 in a state where the coupler base 11a is fitted and supported by the coupler support 3e, the coupler base 11a is supported in a state surrounded by both the coupler supports 3e and 4j. When the secondary injection is performed, the resin material 6 is injected into the stepped portion 3f and the groove portion 3g. The resin material 6 surrounds the periphery of the coupler base portion 11a and the coupler support portions 3e, 4j. Thus, the coupler base 11a and the coupler support portions 3e and 4j are fixed in a sealing manner and integrally formed, whereby a highly waterproof drawer portion is easily formed.

FIG. 12 shows a fourth reference example . That is, as shown in FIG. 12 (A), the outer lens 4 has a butted portion at a tapered surface 4b, a fitting recess 4c, a first end surface portion (contact horizontal surface portion) 4d, and a step surface portion (protruding surface portion). 4e, the second end surface portion (contact horizontal surface portion) 4f is formed, while the outer housing 3 has a tapered surface 3b, a fitting convex portion 3c, and an outer surface portion as shown in FIG. 12B. In the case where the outer housing 3 and the outer lens 4 are brought into contact with each other when the mold is formed for the secondary injection as shown in FIG. 12C, the fitting recess 4c and the fitting projection 3c are formed. And make it fit. In this case, the second-injected resin material 6 includes a first end surface portion (contact horizontal surface portion) 4d, a step surface portion (projecting surface portion) 4e, and a second end surface portion (contact horizontal surface portion) 4f formed on the outer lens 4. And the outer surface portion 3d formed in the outer housing 3 and the flow passage formed by the flow passage forming portion 8c formed in the first mold 8 in this case. When the taper surface 4b formed on the lens 4 and the fitting concave portion 4c are set so that the taper surface 3b formed on the outer housing 3 and the fitting convex portion 3c are displaced to the outside. The fitting recess 4c on the outer lens side is forcibly drawn inward by the fitting projection 3c on the outer housing side and is biased so that the tapered surfaces 3b and 4b come into contact with each other. Space S is formed between the lens outer peripheral surface 2c and the second mold 9 Te.

  Then, as shown in FIG. 12D, the resin material 6 is secondarily injected in this mold-matched state. Here, the resin material 6 is formed on the upper surface of the first mold 8 and the second metal mold. Side surface of mold 9, first end surface portion (contact horizontal surface portion) 4 d formed on outer lens 4, step surface portion (projection surface portion) 4 e, second end surface portion (contact horizontal surface portion) 4 f, and outer surface portion formed on outer housing 3 It is injected into the flow path surrounded by 3d. Further, in this case, it is also injected into the space S formed between the first mold 8 and the outer peripheral surface 2c of the outer lens, thereby increasing the bonding area and increasing the adhesive strength. Since the outer peripheral surface of the molded body is formed to be flush with the outer lens 4 and the outer housing 3, there is no difference in level between the outer lens 4 and the outer housing 3, so that the side blinker with excellent appearance can be obtained. Further, when the outer lens 4 and the outer housing 3 are brought into contact with each other, the fitting concave portion 4c on the outer lens 4 side is forcibly drawn inward by fitting to the fitting convex portion 3c on the outer housing side. As a result, even when heat shrinkage occurs after primary molding, the outer peripheral surface of the space S does not affect the outer peripheral surface because it approaches the mold.

  As an embodiment of the present invention, the outer housing 3 and the outer lens 4 are injection-molded by matching the first mold 8 and the second mold 9, and then the outer housing 3 and the outer lens 4 are made of the first mold. The second injection is performed while being supported by the mold 8 and the second mold 9, and the side blinker 2 is integrally formed. The first injection step is configured to perform the primary injection. The second injection step configured as a secondary injection does not need to be performed as a series of processes in the same mold, but the first injection that forms the outer housing and the outer lens using different molds. After applying the step, the formed outer housing and outer lens are fitted into another mold and abutted, and then the resin material is injected and integrated. In addition, the outer housing may be formed by performing the first injection step and then removing the outer housing from the mold to form a film. Then, the second injection step may be performed after the mold is re-fitted into the original mold or another mold.

(A) and (B) are the whole perspective views of a door mirror, respectively. (A), (B) is the top view and side view which show the state by which the side blinker was attached to the vehicle main body, respectively. (A), (B) is side sectional drawing of the side turn signal attached to a vehicle main body, respectively. It is an exploded view of a side blinker. It is side surface sectional drawing of a side blinker. (A)-(D) is a schematic explanatory drawing which shows the process by which injection molding is carried out by the 1st and 2nd metal mold | die, respectively. (A)-(E) is a schematic explanatory drawing which shows the film-forming process of a side blinker, respectively. (A)-(D) are side surface sectional drawings which show other embodiment of a flow path, respectively. (A), (B) is side sectional drawing which shows the 2nd , 3rd reference example of a side blinker, respectively. It is an exploded view which shows embodiment of a side blinker. (A), (B), (C) is a perspective view showing an implementation form of the side turn signal, respectively, a plan view, a side view. (A)-(D) are principal part side surface sectional drawings which respectively show 4th embodiment of a side blinker.

Explanation of symbols

2 Side blinker 3 Outer housing 4 Outer lens 5 Inner housing 6 Resin material 7 Space part 8 First mold 8c Flow path forming part 9 Second mold 9c Projection part

Claims (1)

After molding a plurality of half-shaped molded bodies in the first injection step between the plurality of molds, the second molded body is butted together and a resin material is injected onto the butted surface In the method of manufacturing an injection molded body, which is integrated in the injection step to manufacture a molded body , a flow path is formed on a butt surface of at least one molded body molded in the first injection step, and a resin is formed in the flow path. When the material is injected in the second injection step, the flow path injected in the second injection step includes the periphery of the embedded part, and the embedded part is molded with the resin material injected in the second injection step. A method for producing an injection-molded body, characterized by being integrated with a body body .

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