JP6914788B2 - Manufacturing method of resin molding mold and manufacturing method of resin lens - Google Patents

Description

The present invention relates to a method for manufacturing a resin molding mold and a method for manufacturing a resin lens.

Conventionally, an overhead console is provided between the driver's seat and the passenger seat on the ceiling of an automobile. Such an overhead console is equipped with a lamp having a light source covered by a resin lens having irregularities capable of diffusing light in order to illuminate a wide area inside the vehicle. Here, Patent Document 1 below discloses a resin lens in which a diffusing material (diffusing material containing acrylic, silicon, or the like as a component) is embedded in a resin. As a result, the light source covered with the resin lens can be made difficult to see from the design surface of the lamp (the light source can be blindfolded by the resin lens). Therefore, the design of the overhead console can be enhanced.

JP-A-2007-238049

However, the resin lens of Patent Document 1 described above has a problem that the degree of diffusion of light emitted from a light source is low. In order to solve this problem, it was considered to put metal (titanium, aluminum, gold, silver, etc.) particles inside the resin instead of the diffusing material. However, in this idea, the light source covered with the resin lens cannot be made difficult to see from the design surface of the lamp (the light source can be seen through the design surface of the lamp), and the degree of diffusion of the light emitted by this light source is low. It was up to.

The present invention is intended to solve such a problem, and an object thereof is a resin lens capable of increasing the degree of diffusion of light emitted by this light source while making the covered light source difficult to see from the design surface of the lamp. It is an object of the present invention to provide a method for producing a resin molding mold and a method for producing a resin lens.

The present invention is intended to achieve the above object, and is configured as follows.
The invention according to claim 1 is a method for manufacturing a resin molding mold capable of molding a resin lens having irregularities. It includes a step of forming irregularities corresponding to the irregularities of the resin lens on the cavity surface of the resin molding die, and a step of thrusting the concave portions of the cavity surface of the resin molding die formed by this step. At least one of the plurality of places where the butt processing is performed changes the phase of the butt processing in the axial direction with respect to the remaining other parts.

According to the invention of claim 1, the apex of the concave portion of the cavity surface has no sagging surface and becomes sharp. Similarly, the convex apex of the cavity surface is sharp because the sagging surface disappears. Therefore, when a resin lens is manufactured using a resin molding die manufactured by this manufacturing method, the molten resin flows firmly into the concave apex and the convex apex, so that the uneven shape of the resin lens is firmly formed. can. As a result, for example, when the light source of the lamp is covered with this resin lens, the covered light source can be obscured from the design surface of the lamp. In addition, the degree of diffusion of light emitted by this light source can be increased.

The invention according to claim 2 is the method for manufacturing a resin molding die according to claim 1, wherein the resin molding die is molded by electrocasting.

According to the invention of claim 2, this resin molding die can be easily molded as compared with the case where the resin molding die is molded by cutting out metal or the like.

The invention according to claim 3 is the method for manufacturing a resin molding die according to any one of claims 1 to 2, wherein the thrusting process is performed by a bite having a polygonal pyramid at the tip. The apex of the polygonal pyramid of the cutting tool is set so as to coincide with the concave sagging surface formed on the cavity surface of the resin molding die.

According to the invention of claim 3, the apex of the concave portion of the cavity surface can be surely made sharp without a sagging surface. Similarly, the convex apex of the cavity surface can be surely made sharp without a sagging surface.

The invention according to claim 4 is the method for manufacturing a resin molding mold according to claim 3, and the polygonal pyramid is a triangular pyramid forming an isosceles triangle in a plan view thereof.

According to the invention of claim 4, among the concave inclined surfaces of the resin molding die formed by the thrusting process, at least one inclined surface can be made different from the remaining two inclined surfaces. Therefore, the effect of claim 1 can be further enhanced.

The invention according to claim 5 is a method for manufacturing a resin lens having irregularities. It includes a step of forming unevenness corresponding to the unevenness of the resin lens on the cavity surface of the resin molding die by piercing, and a step of pouring molten resin into the resin molding die formed by this step. At least one of the plurality of places where the butt processing is performed changes the phase of the butt processing in the axial direction with respect to the remaining other parts .

According to the invention of claim 5, the action and effect of the resin lens according to claim 1 can be obtained.

It is a plan view of the overhead console which concerns on embodiment. FIG. 2 is a cross-sectional view taken along the line II-II of FIG. It is a figure explaining the manufacturing process of the resin molding mold which molds the resin lens of FIG. It is a figure explaining the next process of FIG. It is a figure explaining the next process of FIG. It is a figure explaining the next process of FIG. It is a perspective view of the bite of FIG. It is a top view of the bite of FIG. It is a perspective view of another form of a bite. It is a top view of the bite of FIG.

Hereinafter, embodiments for carrying out the present invention will be described with reference to FIGS. 1 to 8. First, the overhead console 1 according to the embodiment will be described with reference to FIGS. 1 and 2.

The overhead console 1 is composed of interior members provided between a driver's seat and a passenger seat (neither shown) on the ceiling of an automobile. Such an overhead console 1 mainly corresponds to a storage case 2 capable of storing articles (for example, sunglasses, etc.) inside the overhead console 1, a room lamp 3 capable of illuminating the inside of the vehicle, and a driver's seat and a passenger seat. It is composed of left and right map lamps 4.

As is clear from FIG. 2, the light source 3a of the room lamp 3 is provided on the substrate 6 assembled on the inner surface of the box panel 5 of the overhead console 1. The substrate 6 is provided with a guide 7 that is shaped to block the front and rear of the light source 3a of the room lamp 3. A resin lens 8 is attached to both guides 7 so as to bridge the tips thereof. When assembled in this way, the room lamp 3 is covered with the resin lens 8.

On the surface of the resin lens 8 (the light transmitting surface emitted by the light source 3a), a plurality of irregularities 8a capable of diffusing the light emitted by the light source 3a are formed. As a result, the room lamp 3 can illuminate a wide area inside the vehicle. The light source 3a of the room lamp 3 is electrically configured to be turned ON (lighted) or OFF (turned off) when the door (not shown) of the automobile is opened or closed.

On the other hand, the map lamp 4 is also configured in the same manner as the room lamp 3. The light source 4a of the map lamp 4 is electrically configured to be turned ON (ON) or OFF (OFF) by operating the left and right switches 9 provided on the overhead console 1.

Here, a method of manufacturing the resin lens 8 of the overhead console 1 will be described with reference to FIGS. 3 to 8. The resin lens 8 is molded using the resin molding mold 10. Therefore, first, a method for manufacturing the resin molding die 10 will be described with reference to FIGS. 3 to 6.

First, the work of molding the master material 20 having the same shape as the resin lens 8 to be manufactured is performed (see FIG. 3). Since the master material 20 has the same shape as the resin lens 8, a plurality of irregularities 21 are formed on the molded master material 20 as well as the plurality of irregularities 8a formed on the resin lens 8. There is. The distance between the adjacent concave 22 and the convex 23 in the plurality of unevenness 21 is small (for example, several mm).

Therefore, the apex of the concave 22 is a sagging surface 22a without being sharp. Similarly, the apex of the convex 23 is also a sagging surface 23a without being sharp. The master material 20 is molded of metal or synthetic resin. Next, a known electroforming operation is performed on the molded master material 20 (see FIG. 4). As a result, a member having the same shape as the master material 20, that is, a resin molding die 10 capable of molding the resin lens 8 is completed (see FIG. 5).

That is, the resin molding die 10 can be molded by electroforming. On the cavity surface 10a of the completed resin molding die 10, the unevenness 11 to which the unevenness 21 of the master material 20 is transferred is formed. Therefore, the apex of the concave 12 is a sagging surface 12a without being sharp like the apex of the concave 22 of the master material 20. Similarly, the apex of the convex 13 is also a sagging surface 13a without being sharp like the apex of the convex 23 of the master material 20.

Finally, the concave 12 of the cavity surface 10a of the completed resin molding die 10 is sequentially pierced by the cutting tool 30 (see FIG. 6). When the thrusting process is performed in this way, the apex of the concave portion 12 of the cavity surface 10a of the resin molding die 10 becomes sharp because the sagging surface 12a disappears. Similarly, the apex of the convex 13 of the cavity surface 10a of the resin molding die 10 also becomes sharp because the sagging surface 13a disappears.

As is clear from FIG. 7, the bite 30 is formed so that its tip is a triangular pyramid. This triangular pyramid is formed so that its plan view is an isosceles triangle (see FIG. 8). The apex 31 of the triangular pyramid of the bite 30 is set so as to coincide with the sagging surface 12a of the concave portion 12 formed on the cavity surface 10a of the resin molding die 10 (see FIG. 6). Further, when this thrusting process is performed in order, the phase of the bite 30 is changed for each of the adjacent recesses 12.

As an example of changing this phase, for example, as shown in FIG. 6, if the phase angle of the bite 30 is "0 °" in the state of (a), the phase angle of the bite 30 is set in the state of (b). It becomes "90 °", and in the state of (c), the phase angle of the bite 30 is "180 °", and in the state of (d), the phase angle of the bite 30 is "270 °". When the phase of the bite 30 is changed in this way, the angle of the inclined surface of the unevenness 11 becomes different. The resin molding die 10 is manufactured in this way.

A resin lens 8 is completed by injecting a molten resin (not shown) composed of transparent or translucent pellets into the resin molding die 10 manufactured in this manner and cooling and solidifying the injected molten resin. The resin lens 8 is manufactured in this way.

The method for manufacturing the resin molding die 10 according to the embodiment of the present invention is manufactured by the above-mentioned manufacturing method. According to this manufacturing method, a step of thrusting the concave portion 12 of the cavity surface 10a of the resin molding die 10 with a cutting tool 30 is provided. Therefore, the apex of the concave 12 of the cavity surface 10a becomes sharp because the sagging surface 12a disappears. Similarly, the apex of the convex 13 of the cavity surface 10a also becomes sharp because the sagging surface 13a disappears. Therefore, when the resin lens 8 is manufactured using the resin molding mold 10 manufactured by this manufacturing method, the molten resin flows firmly into the apex of the concave 12 and the apex of the convex 13, so that the unevenness 8a of the resin lens 8 Can form the shape of. As a result, when the light source 3a of the room lamp 3 is covered with the resin lens 8, the covered light source 3a can be made difficult to see from the design surface of the room lamp 3. In addition, the degree of diffusion of light emitted by the light source 3a can be increased.

Further, according to this manufacturing method, the resin molding die 10 is molded by electroforming. Therefore, the resin molding die 10 can be easily molded as compared with the case where the resin molding die 10 is molded by cutting out metal or the like.

Further, according to this manufacturing method, the apex 31 of the triangular pyramid of the bite 30 is set so as to coincide with the sagging surface 12a of the concave 12 formed in the cavity surface 10a of the resin molding die 10. Therefore, the apex of the concave portion 12 of the cavity surface 10a can be surely made sharp without the sagging surface 12a. Similarly, the apex of the convex 13 of the cavity surface 10a can be surely made sharp without the sagging surface 13a.

Further, according to this manufacturing method, the bite 30 is formed so that the tip thereof is a triangular pyramid. This triangular pyramid is formed so that its plan view is an isosceles triangle. Therefore, among the three inclined surfaces of the concave 12 of the resin molding die 10 formed by the thrusting process, one inclined surface can be made different from the remaining two inclined surfaces. Therefore, in the completed resin lens 8, the degree of diffusion of the light emitted by the light source 3a can be further increased.

The above-mentioned contents are merely related to one embodiment of the present invention, and do not mean that the present invention is limited to the above-mentioned contents.

In the embodiment, the embodiment in which the “resin lens 8” is the “resin lens 8 of the overhead console 1” has been described. However, the present invention is not limited to this, and the "resin lens" may be a "resin lens of various interior members, exterior members (for example, rear lamp, vanity lamp, etc.)".

Further, in the embodiment, the embodiment in which the "tip of the bite 30" is a "triangular pyramid" has been described. However, the present invention is not limited to this, and the "tip of the bite" may be a "quadrangular pyramid" (see FIGS. 9 to 10). Of course, it is not limited to these "triangular pyramids" and "square weights", and any "polygonal weight" may be used.

Further, in the embodiment, as an example of changing the phase of the bite 30, a mode in which the phase angle of the bite 30 is changed by "90 °" has been described. However, the present invention is not limited to this, and may be "30 °", "45 °", "60 °", or the like. Of course, it can be random.

8 Resin lens 8a Concavo-convex 10 Resin molding mold 10a Cavity surface 11 Concavo-convex 12 Concave

Claims (5)

A method for manufacturing a resin molding mold capable of molding a resin lens having irregularities.
A step of forming irregularities corresponding to the irregularities of the resin lens on the cavity surface of the resin molding mold, and
It is provided with a step of plunging the concave portion of the cavity surface of the resin molding die formed by the step.
A method for manufacturing a resin molding die in which the phase of the thrusting process in the axial direction is changed with respect to the remaining other locations at least one of the plurality of locations where the thrusting process is performed. The method for manufacturing a resin molding die according to claim 1.
The resin molding die is a method for manufacturing a resin molding die formed by electroforming. The method for manufacturing a resin molding die according to any one of claims 1 and 2.
The thrusting process is performed by a bite whose tip is a polygonal pyramid.
A method for manufacturing a resin molding die, in which the vertices of the polygonal pyramids of the bite are set to coincide with the concave sagging surface formed on the cavity surface of the resin molding die. The method for manufacturing a resin molding die according to claim 3.
The method for manufacturing a resin molding mold, wherein the polygonal pyramid is a triangular pyramid forming an isosceles triangle in the plan view. A method for manufacturing a resin lens having irregularities.
A process of forming irregularities corresponding to the irregularities of the resin lens on the cavity surface of the resin molding die by piercing.
It includes a step of pouring a molten resin into the resin molding die formed by the step .
A method for manufacturing a resin lens in which the phase of the thrusting process in the axial direction is changed with respect to the remaining other locations at least one of the plurality of locations where the thrusting process is performed.

Images