JP7240259B2 - Two-color molding lens - Google Patents

Description

TECHNICAL FIELD The present invention relates to a two-color molded lens having an anti-fogging coating film formed on its inner surface.

2. Description of the Related Art Conventionally, a two-color molded lens is known which consists of a primary molded product made of transparent resin and a secondary molded product made of opaque resin.

As a two-color molded lens used for a vehicle lamp, for example, as described in "Patent Document 1", a lens body portion and a lens peripheral wall portion rising from the peripheral edge portion to the inner surface side of the two-color molded lens are provided. It is common to have a configuration with

In such a two-color molded lens, the primary molded product is formed along the outer surface of the two-color molded lens so as to extend from the lens main body portion to the lens peripheral wall portion, and the secondary molded product is the two-color molded lens. It is formed so as to extend from the lens peripheral wall portion to the lens main body portion along the inner surface of the lens.

Conventionally, headlamp lenses for vehicle lamps have often adopted a configuration in which a hard coat film is formed on the outer surface and an anti-fogging coating film is formed on the inner surface.

These film-forming operations include, for example, as described in "Patent Document 2", after forming a hard coat film on the outer surface of the lens, the synthetic resin composition in the paint is cured by ultraviolet irradiation, and then, It is common to form an anti-fog coating film on the inner surface of the lens and then harden the anti-fog coating film by heat (hereinafter referred to as "independent film forming process"). be.

JP 2014-176974 A Japanese Patent Application Laid-Open No. 2000-182409

As a two-color molded lens, when a hard coat film is formed on the outer surface and an anti-fogging coating film is formed on the inner surface, the film forming process is the same as the conventional independent film forming process. Instead, after forming a hard coat film on the outer surface of the two-color molded lens, an anti-fogging coating film is formed on the inner surface, and then the hard coating film is cured by ultraviolet irradiation, and then the anti-fogging coating film is applied. Employing a process of curing by heat (hereinafter referred to as a "hybrid film forming process") can save manpower in the film forming process, thereby improving work efficiency in the manufacturing process of two-color molded lenses. be able to.

However, when such a hybrid film formation process is employed, the following problems arise.

That is, in a two-color molded lens, the secondary molded product is molded after the primary molded product is molded. R is inevitably formed and cannot be formed at the pin angle (ie, R0). At that time, in normal mold processing, the minimum corner radius is approximately 0.3 mm due to the structure of the end mill.

Therefore, in the two-color molded lens, groove-like gaps having a substantially wedge-shaped cross section are formed along the corners of the primary molded product.

Under these circumstances, when the hybrid film formation process is adopted, the anti-fogging coating film is cured after the hard coat film is cured by UV irradiation. The anti-fogging paint accumulated in the groove-shaped gaps formed at the corners of the molded product impregnates the inside of the primary molded product, which makes cracks more likely to occur around the corners of the primary molded product.

In particular, when molding a secondary molded product, the primary molded product placed in the mold receives a pressing force from the molten resin injected into the mold. In this case, residual stress is generated around the corners of the primary molded product, which makes cracks more likely to occur.

If cracks are generated around the corners of the primary molded product in this manner, the cracks can be seen through the transparent lens main body, resulting in poor appearance of the two-color molded lens.

Even when a separate film forming process is adopted, or when a two-color molded lens is configured without a hard coat film on the outer surface, the inner surface of the lens is protected against such problems. A similar problem may occur if a certain amount of time or more is required until the hardening of the cloudy coating film is completed after it is formed.

The present invention has been made in view of such circumstances, and is a two-color molded lens having an anti-fogging coating film formed on the inner surface, which can effectively suppress the occurrence of poor appearance. The object is to provide a molded lens.

The present invention is intended to achieve the above object by devising the configuration of the secondary molded product.

That is, the two-color molded lens according to the present invention is
A two-color molded lens comprising a primary molded product made of transparent resin and a secondary molded product made of opaque resin. A two-color molded lens having a rising lens peripheral wall portion and an anti-fogging coating film formed on the inner surface,
The primary molded product is formed so as to extend from the lens main body portion to the lens peripheral wall portion along the outer surface of the two-color molded lens,
The secondary molded product is formed so as to extend from the lens peripheral wall portion to the lens body portion along the inner surface of the two-color molded lens,
The joint surface between the inner peripheral end surface of the primary molded product and the outer peripheral end surface of the secondary molded product on the inner surface side of the two-color molded lens is located in the lens body portion from the outer surface side of the two-color molded lens. formed to extend to the inner surface of the two-color molded lens,
The secondary molded product is formed with a covering portion extending from the joint surface with the primary molded product along the inner surface of the primary molded product so as to cover the primary molded product. It is characterized.

The above-mentioned "two-color molded lens" is formed so that the primary molded product extends from the lens main body to the lens peripheral wall along the outer surface of the two-color molded lens, and the secondary molded product is inside the two-color molded lens. The specific shape is not particularly limited as long as it is formed so as to extend from the lens peripheral wall portion to the lens body portion along the surface.

The "lens peripheral wall portion" may be formed over the entire circumference of the peripheral edge portion of the lens main body portion, or may be formed in a portion thereof.

The specific shape of the "covering portion" is not particularly limited as long as it extends from the joint surface with the primary molded product along the inner surface thereof so as to cover the primary molded product.

In the two-color molded lens according to the present invention, the secondary molded product is formed so as to extend from the lens peripheral wall portion to the lens main body along the inner surface thereof, and the primary molded product is attached from the joint surface with the primary molded product. Since the covering portion extending along the inner surface so as to cover the primary molded product is formed to extend, it is possible to prevent the formation of groove-like gaps at the corners of the primary molded product. can.

Therefore, even if it takes more than a certain amount of time to complete the curing after the anti-fog coating film is formed on the inner surface of the lens, cracks around the corners of the primary molded product will not occur. It is possible to effectively suppress the occurrence of cracks, thereby effectively suppressing the occurrence of poor appearance due to the occurrence of cracks.

As described above, according to the present invention, it is possible to effectively suppress the occurrence of poor appearance in a two-color molded lens having an anti-fogging coating film formed on the inner surface.

In the above configuration, if the two-color molded lens is configured such that a hard coat film is formed on the outer surface, the following effects can be obtained.

That is, in a two-color molded lens having a hard coat film formed on the outer surface and an anti-fogging coating film formed on the inner surface, when these film forming operations are performed by a hybrid film forming process, It takes a relatively long time from the formation of the anti-fogging coating film to the completion of its curing. , it is possible to effectively suppress the occurrence of poor appearance due to the occurrence of cracks. Therefore, by adopting the hybrid type film forming process, it is possible to save manpower in the film forming process, thereby improving the working efficiency in the manufacturing process of the two-color molded lens.

In the above configuration, if the covering portion of the secondary molded product is further configured so that the front end surface extends obliquely toward the inner surface of the primary molded product, the secondary molded product can be It is possible to provide a structure in which the antifogging paint is less likely to accumulate on the connecting portion between the covering portion and the inner surface of the primary molded product. Therefore, it is possible to effectively suppress the impregnation of the anti-fogging paint accumulated in the connecting portion into the interior of the primary molded product, and as a result, cracks are generated around the corners of the primary molded product. It is possible to more effectively suppress the storage.

At that time, if the inclination angle of the tip surface of the covering portion is set to 30 to 60°, when molding the secondary molded product, the molten resin can be sufficiently filled into the covering portion. Therefore, it is possible to enhance the effect of making it difficult for the anti-fogging paint to accumulate on the connecting portion between the tip surface of the covering portion of the secondary molded product and the inner surface of the primary molded product.

In the above configuration, the corner R formed at the corner between the inner surface of the primary molded product and the joint surface of the secondary molded product is set to a value of R 0.1 to 0.5 mm. Then, when molding the secondary molded product, the covering part extended from the joint surface between the primary molded product and the secondary molded product after sufficiently ensuring the filling property of the molten resin into the covering part. It is possible to reduce the covering width of the lens body, thereby making it possible to effectively utilize a larger portion of the lens body as a transparent region.

In the above configuration, if the angle between the joint surface of the primary molded product and the secondary molded product and the inner surface of the primary molded product is set to a value of 100 ° or more, the secondary molded product When molding the, it is possible to improve the filling property of the molten resin to the covering portion.

In the above configuration, further, as the configuration of the primary molded product, the inner surface of the two-color molded lens has an annular region along the joint surface with the secondary molded product, which is located on the inner peripheral side of the annular region. A corner portion (hereinafter also referred to as a "second corner") between the inner surface of the general area and the inner peripheral surface of the thick portion after having a configuration formed as a thick portion that is stepped on the side. With a configuration in which a corner R of 0.2 mm or more is formed at the edge, the following effects can be obtained.

That is, in order to manufacture a two-color molded lens with high accuracy, it is essential to maintain the position of the primary molded product in the mold when molding the secondary molded product.

In order to achieve this, as a configuration of the primary molded product, an annular region along the joint surface with the secondary molded product is formed as a thick portion, and when molding the secondary molded product, the thick portion is formed. Conventionally, a method of positioning a primary molded product by pressing a mold has been adopted.

However, since the thick portion is somewhat crushed when the mold is pressed against it, stress concentration occurs in the second corner of the primary molded product, and as a result, the periphery of the second corner is crushed. Cracks may occur in the area.

On the other hand, if the second corner is formed with a corner R of 0.2 mm or more as the primary molded product, even if the thick part is crushed to some extent, stress concentration will occur at the second corner. It is possible to prevent this from happening. Therefore, it is possible to effectively suppress the occurrence of cracks in the peripheral region of the second corner, thereby effectively suppressing the occurrence of poor appearance due to the occurrence of cracks.

1 is a front view showing a two-color molded lens according to one embodiment of the present invention; II-II line sectional view of Fig. 1 Detailed view of part III in Fig. 2 (a) is a detailed view of part IV in FIG. 3, and (b) is a view similar to (a) showing the state of molding the secondary molded product of the two-color molded lens. (a1) to (a3) are diagrams showing the manufacturing process of the two-color molded lens, and (b1) to (b4) are diagrams showing the conventional manufacturing process in comparison with (a1) to (a3). (a1) is a detailed view of the VI part of FIG. 3, (b1) is a view similar to (a1) showing the state of molding the secondary molded product, (a2) and (b2) are comparisons of the above embodiments. Figures similar to (a1) and (b1) showing examples FIG. 4A is a view similar to FIG. 4A showing first and second modifications of the above embodiment;

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a front view showing a two-color molded lens 10 according to one embodiment of the present invention, and FIG. 2 is a cross-sectional view taken along line II-II of FIG.

In these figures, the direction indicated by X is the "forward" direction of the two-color molded lens 10, and the direction indicated by Y is the "leftward direction" ("rightward direction" when viewed from the front of the lens) perpendicular to the "forward" direction. , Z is the "upward direction". The same applies to figures other than these.

As shown in FIG. 1, the two-color molded lens 10 according to the present embodiment is a translucent cover of a headlamp arranged at the right front end of a vehicle, and is made of transparent resin (for example, made of colorless and transparent PC resin, etc.). ) and a secondary molded product 10S made of an opaque resin (for example, black PC resin or ABS resin).

The two-color molded lens 10 includes a lens body portion 12 formed in a horizontally elongated substantially rectangular shape when viewed from the front of the lamp, and an inner surface 10b side of the two-color molded lens 10 from the outer peripheral edge of the lens body portion 12 (that is, the rear side of the lens). ) and an outer peripheral flange portion 16 extending from the rear end position of the lens peripheral wall portion 14 toward the outer peripheral side. When the two-color molded lens 10 is mounted on a vehicle, the lens body 12 forms a design surface extending along the surface shape of the vehicle.

As shown in FIG. 2, the primary molded product 10P is formed along the outer surface 10a of the two-color molded lens so as to extend from the lens main body portion 12 to the lens peripheral wall portion 14, while the secondary molded product 10S is formed. is formed so as to extend from the lens peripheral wall portion 14 to the lens main body portion 12 along the inner surface 10b of the two-color molded lens.

A joint surface 10a1 between the primary molded product 10P and the secondary molded product 10S on the side of the outer surface 10a of the two-color molded lens 10 is located substantially in the center between the lens main body portion 12 and the outer peripheral flange portion 16 in the lens peripheral wall portion 14. ing. On the other hand, the joint surface 10b1 between the primary molded product 10P and the secondary molded product 10S on the inner surface 10b side of the two-color molded lens 10 is positioned near the peripheral edge of the lens main body 12. As shown in FIG.

The two-color molded lens 10 according to this embodiment has a hard coat film 22 formed on its outer surface 10a and an antifogging coating film 24 formed on its inner surface 10b. At that time, the hard coat film 22 is formed so as to cover the entire area of the primary molded product 10P, and the anti-fogging coating film 24 is also formed so as to cover the entire area of the primary molded product 10P.

Before describing the detailed structure of the two-color molded lens 10, its manufacturing process will be described.

FIGS. 5(a1) to 5(a3) are diagrams showing a hybrid film forming process as a process of performing a film forming operation on the two-color molded lens 10 after completion of molding.

In this hybrid type film forming process, in the first step shown in FIG. 5(a1), after forming a hard coat film 22 on the outer surface 10a of the two-color molded lens 10, an antifogging coating film 24 is formed on the inner surface 10b. Next, in the second step shown in FIG. 5(a2), the hard coat film 22 is cured by ultraviolet irradiation, and finally in the third step shown in FIG. 5(a3), the antifogging coating film 24 is hardened by heat.

In the first step shown in FIG. 5(a1), the hard coat film 22 was formed while the two-color molded lens 10 was placed on a jig (not shown) set on a turntable (not shown). After that, the turntable is rotated by 180°, and the anti-fogging coating film 24 is formed in this state.

The hard coat film 22 is formed by moving the nozzle 102 of the spray gun along the outer surface 10a of the two-color molded lens 10 and spraying the hard coat paint P1 from the nozzle 102 onto the outer surface 10a. ing.

At that time, as the hard coat paint P1, for example, an acrylic hard coat paint composed of an acrylic monomer, an ultraviolet absorber, a light stabilizer, a polymerization initiator, a solvent, or the like can be used.

The antifogging coating film 24 is formed by moving the nozzle 104 of the spray gun along the inner surface 10b of the two-color molded lens 10 and spraying the antifogging coating P2 from the nozzle 104 onto the inner surface 10b. It's like

In this case, as the anti-fogging paint P2, for example, an acrylic anti-fogging paint made of an acrylic resin, a surfactant, a curing agent (catalyst), or the like can be used.

In the second step shown in FIG. 5(a2), the outer surface 10a of the two-color molded lens 10 is irradiated with ultraviolet rays from the ultraviolet irradiation device 106 so as to cure the hard coat film 22 applied to the outer surface 10a. It's becoming Prior to this ultraviolet irradiation, the two-color molded lens 10 may be heated by infrared irradiation or the like.

In the third step shown in FIG. 5(a3), the two-color molded lens 10 is placed in a heating furnace 108 and the inner surface 10b is heated with hot air of about 120° C., thereby removing the anti-fog coating applied to the inner surface 10b. The coating film 24 is cured.

The second and third steps are continuously performed by conveying the two-color molded lens 10 on a roller conveying path (not shown).

In this hybrid-type film forming process, in addition to the inspection personnel after the film formation, there is a staff member for transferring the two-color molded lens 10 from the turntable to the roller conveying path between the first process and the second process. One worker 2 is arranged.

On the other hand, FIGS. 5(b1) to 5(b4) are diagrams showing an independent film forming process conventionally performed as a process of performing a film forming operation on the two-color molded lens 10 after completion of molding.

First, in the first step shown in FIG. 5(b1), while moving the nozzle 102 of the spray gun along the outer surface 10a of the two-color molded lens 10, the hard coat paint P1 is sprayed from the nozzle 102 onto the outer surface 10a. Thus, a hard coat film 22 is formed on the outer surface 10a.

Next, in a second step shown in FIG. 5B2, the outer surface 10a of the two-color molded lens 10 is irradiated with ultraviolet rays from the ultraviolet irradiation device 106, thereby curing the hard coat film 22 applied to the outer surface 10a. It is designed to let

Next, in the third step shown in FIG. 5(b3), while moving the nozzle 104 of the spray gun along the inner surface 10b of the two-color molded lens 10, the antifogging paint P2 is applied from the nozzle 104 to the inner surface 10b. By spraying, an anti-fogging coating film 24 is formed on the inner surface 10b.

Finally, in the fourth step shown in FIG. 5(b4), the two-color molded lens 10 is put into the heating furnace 108 and the inner surface 10b is heated with hot air of about 120° C., thereby coating the inner surface 10b. The anti-fogging coating film 24 is cured.

In this independent film formation process, in addition to inspection personnel after the film formation, there is a task of transferring the two-color molded lens 10 from the hard coating booth to the UV irradiation booth between the first process and the second process. In addition, between the third and fourth processes, a worker 2 is arranged to transfer the two-color molded lens 10 from the anti-fogging coating booth to the heating furnace 108. It is designed to be placed. Furthermore, workers 2 are arranged between the second process and the third process as needed.

By switching the independent film formation process to the hybrid film formation process, it is possible to reduce the number of workers 2 by at least one.

Next, the detailed structure of the two-color molded lens 10 will be described.

FIG. 3 is a detailed view of part III in FIG.

As shown in FIG. 3, in the primary molded product 10P, the annular region along the joint surface 10b1 is formed as a thick portion 10Pa that is stepped rearward of the lens with respect to the general region on the inner peripheral side. ing.

On the other hand, in the secondary molded product 10S, the body-side wrap-around portion 10Sa that wraps around to the lens body portion 12 side has an inner surface 10Sa1 that is behind the lens with respect to the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P. It is formed so as to step up to the side and extend substantially parallel to the inner surface 10Pa1.

In addition, a covering portion 10Sb extends along the inner surface 10Pa1 of the thick portion 10Pa from the joint surface 10b1 with the primary molded product 10P so as to cover the thick portion 10Pa. Formed as an extension.

FIG. 4(a) is a detailed view of part IV in FIG.

As shown in FIG. 4A, in the primary molded product 10P, the included angle θ1 between the inner surface 10Pa1 of the thick portion 10Pa and the joint surface 10b1 is a value of 100° or more (for example, a value of about 120°). is set to

Further, in the primary molded product 10P, a corner portion 10Pb between the inner surface 10Pa1 of the thick portion 10Pa and the joint surface 10b1 has a thickness of about RA=R0.1 to 0.5 mm (for example, about RA=R0.3 mm). A corner R is formed.

The corner portion 10Pb is formed at a position about 1 to 3 mm (for example, about 2 mm) away from the connection position 10c between the lens main body portion 12 and the lens peripheral wall portion 14 on the inner surface 10b side of the two-color molded lens 10.

On the other hand, the covering portion 10Sb of the secondary molded product 10S is formed such that its tip end surface 10Sb1 extends obliquely toward the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P. At that time, the inclination angle θ2 of the tip surface 10Sb1 of the covering portion 10Sb is set to a value of approximately 30 to 60° (for example, a value of approximately 45°).

In addition, the covering width of the covering portion 10Sb (that is, the width from the R stop position on the joint surface 10b1 side of the corner portion 10Pb to the tip position of the tip surface 10Sb1) W is a value of about 0.5 to 1 mm (for example, 0.8 mm value).

The covering thickness (that is, the thickness in the front-rear direction of the lens) T of the covering portion 10Sb is the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P and the inner surface 10Sa1 of the main body side wrap portion 10Sa of the secondary molded product 10S. and is set to a value of about 0.4 to 1 mm (for example, a value of about 0.5 mm).

The anti-fogging coating film 24 is applied to the entire area of the primary molded product 10P portion of the inner surface 10b of the two-color molded lens 10, the inner surface 10Sa1 of the body-side winding portion 10Sa of the secondary molded product 10S, and the tip of the covering portion 10Sb. It is formed so as to cover the entire region of the surface 10Sb1 and the front end region of the inner surface of the lens peripheral wall portion .

FIG. 4(b) is a view similar to FIG. 4(a), showing how the secondary molded product 10S of the two-color molded lens 10 is molded.

As shown in FIG. 4(b), the secondary molded product 10S is formed between the secondary molding die 100 and the primary molded product 10P placed in the die 100. It is formed by injecting the molten resin Rs into the space C for secondary molding.

At that time, the mold 100 is arranged while being pressed against the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P. The molten resin Rs is filled to every corner of the secondary molding space C so as to wrap around the surface of the mold 100, and the secondary molding space for forming the covering portion 10Sb of the secondary molded product 10S. Cb is also filled.

When the secondary molded product 10S is molded in this manner, the primary molded product 10P is subjected to a pressing force F on the joint surface 10b1 by the molten resin Rs filled in the secondary molding space C. In the two-color molded lens 10, residual stress tends to occur around the corners 10Pb of the primary molded product 10P.

In this respect, in the present embodiment, when the molding of the secondary molded product 10S is completed, the covering portion 10Sb is formed so as to cover the corner portion 10Pb of the primary molded product 10P. The risk of cracks occurring in the periphery is minimized.

When molding the secondary molded product 10S, the thick portion 10Pa of the primary molded product 10P is pressed by the mold 100. Therefore, the two-color molded lens 10 after the completion of molding is the primary molded product 10P. In the inner surface 10Pa1 of the thick portion 10Pa, the portion against which the mold 100 was pressed is slightly displaced (for example, about 0.1 to 0.15 mm) toward the outer surface 10a than the other portions.

FIG. 6(a1) is a detailed view of the VI part in FIG.

As shown in FIG. 6(a1), in the primary molded product 10P, the corner portion (that is, the second The corner portion 10Pc is formed with a corner R of RB=R0.2 mm or more (for example, RB=R about 0.2 to 0.8 mm).

FIG. 6(b1) is a view similar to FIG. 6(a1), showing how the secondary molded product 10S of the two-color molded lens 10 is molded.

As shown in FIG. 6(b1), when molding the secondary molded product 10S, the mold 100 is pressed against the thick portion 10 Pa of the primary molded product 10P. is somewhat crushed, and its inner surface 10Pa1 is displaced from the position indicated by the two-dot chain line in the drawing to the position indicated by the solid line in the drawing. Along with this, the corner 10Pc is also somewhat crushed, so the corner R is somewhat smaller than the original corner R (that is, the corner R indicated by the two-dot chain line in the figure), but the corner 10Pc has an RB=R of 0.2 mm. The state in which the above corners R are formed is maintained.

FIGS. 6A2 and 6B2 are similar to FIGS. 6A1 and 6B1 showing comparative examples of the present embodiment.

As shown in FIG. 6(a2), hypothetically, in the primary molded product 10P, the corner 10Pc between the inner peripheral surface 10Pa2 of the thick portion 10Pa and the inner surface 10b of the general area located on the inner peripheral side is If only the pin angle or the corner R close to the pin angle was formed, when molding the secondary molded product 10S, as shown in FIG. When the thick portion 10Pa is pressed against the thick portion 10Pa and is somewhat crushed, the inner surface 10Pa1 of the thick portion 10Pa is displaced from the position indicated by the two-dot chain line in the drawing to the position indicated by the solid line in the drawing. Stress concentration occurs in the peripheral region Asc of the corner 10Pc.

Therefore, as shown in FIG. 6(a2), when the anti-fogging coating film 24 is subsequently formed, cracks CR may occur in the peripheral region Asc of the corner 10Pc due to the stress concentration.

Next, the effects of this embodiment will be described.

In the two-color molded lens 10 according to the present embodiment, 1 Since the covering portion 10Sb extending from the joint surface 10b1 with the next molded product 10S along the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P so as to cover the primary molded product 10P, 1 It is possible to prevent a groove-like gap from being formed at the corner 10Pb of the next molded product 10P.

Therefore, even if it takes a certain amount of time or more to complete the curing after the antifogging coating film 24 is formed on the inner surface 10b of the two-color molded lens 10, the primary molded product It is possible to effectively suppress the occurrence of cracks around the corner 10Pb of 10P, thereby effectively suppressing the occurrence of poor appearance due to the occurrence of cracks.

As described above, according to the present embodiment, it is possible to effectively suppress the occurrence of poor appearance in the two-color molded lens 10 having the anti-fogging coating film formed on the inner surface 10b.

In particular, since the two-color molded lens 10 according to the present embodiment has a configuration in which the hard coat film 22 is formed on the outer surface 10a, the following effects can be obtained.

That is, in the two-color molded lens 10 having the hard coat film 22 formed on the outer surface 10a and the anti-fogging coating film 24 formed on the inner surface 10b, these film forming operations are performed by a hybrid film forming process. In this case, it takes a relatively long time from the formation of the anti-fogging coating film 24 to the completion of its curing. Since there is no groove-like gap in 10Pb, it is possible to effectively suppress the occurrence of poor appearance due to cracks. Therefore, by adopting the hybrid type film forming process, it is possible to save manpower in the film forming process, thereby improving the work efficiency in the manufacturing process of the two-color molded lens 10 .

In addition, since the covering portion 10Sb of the secondary molded product 10S is formed so that the tip surface 10Sb1 thereof extends at an angle toward the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P, this tip surface The anti-fogging paint is less likely to accumulate in the connecting portion between 10Sb1 and the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P. Therefore, it is possible to effectively suppress the impregnation of the anti-fogging paint accumulated in the connecting portion into the interior of the primary molded product 10P, and as a result, cracks occur around the corners 10Pb of the primary molded product 10P. It is possible to more effectively prevent it from occurring.

At that time, since the inclination angle θ2 of the tip end surface 10Sb1 of the covering portion 10Sb is set to 30 to 60°, when the secondary molded product 10S is molded, the filling of the covering portion 10Sb with the molten resin Rs is improved. After sufficiently ensuring the effect of preventing the anti-fogging paint from accumulating at the connection portion between the tip surface 10Sb1 of the covering portion 10Sb of the secondary molded product 10S and the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P can be enhanced.

In this embodiment, the corner R formed at the corner portion 10Pb between the inner surface 10Pa1 of the thick portion 10Pa of the primary molded product 10P and the joint surface 10b1 of the secondary molded product 10S is RA=R0.1. Since it is set to a value of ~0.5 mm, when the secondary molded product 10S is molded, the molten resin Rs is sufficiently filled into the covering portion 10Sb, and the primary molded products 10P and 2 The covering width W of the covering portion 10Sb extending from the joint surface 10b1 with the next molded product 10S can be kept small, so that a larger portion of the lens main body portion 12 can be effectively used as a transparent region. .

Further, in the present embodiment, the included angle between the joint surface 10b1 between the primary molded product 10P and the secondary molded product 10S and the inner surface 10b of the primary molded product 10P is set to a value of 100° or more. When molding the secondary molded product 10S, the filling property of the molten resin Rs into the covering portion 10Sb can be improved.

In the present embodiment, the primary molded product 10P is formed with the thick portion 10Pa, so that the primary molded product 10P remains positioned in the mold 100 when the secondary molded product 10S is molded. This makes it possible to manufacture the two-color molded lens 10 with high precision, but the corners ( That is, since the second corner 10Pc is formed with a corner R of RB=R0.2 mm or more, the following effects can be obtained.

That is, when molding the secondary molded product 10S, the thick portion 10Pa of the primary molded product 10P is somewhat crushed by being pressed against the mold 100, but the corner portion 10Pc has a thickness of RB=R of 0.2 mm or more. Since the corner R is formed, even if the thick portion 10Pa is crushed to some extent, it is possible to prevent stress concentration from occurring at the corner portion 10Pc. Therefore, it is possible to effectively suppress the occurrence of cracks around the corner portion 10Pc due to this stress concentration, thereby effectively suppressing the occurrence of appearance defects caused by cracks.

In the above embodiment, the two-color molded lens 10 has been described as a translucent cover for a vehicle headlamp, but the same effect as the above embodiment can be obtained even if it is used for other purposes. can.

In the above embodiment, the hard coat film 22 is formed on the outer surface 10a of the two-color molded lens 10, but it is also possible to adopt a configuration in which the hard coat film 22 is not formed. be.

Next, a modification of the above embodiment will be described.

First, a first modified example of the above embodiment will be described.

FIG. 7(a) is a view similar to FIG. 4(a), showing a main part of a two-color molded lens according to this modified example.

As shown in FIG. 7A, the basic configuration of this modification is the same as that of the above embodiment, but the configuration of the secondary molded product 110S is partially different from that of the above embodiment.

That is, also in this modification, from the joint surface 10b1 with the primary molded product 10P to the main body side winding portion 110Sa of the secondary molded product 110S, along the inner surface 10Pa1 of the thick portion 10Pa, to the primary molded product 10P. A covering portion 110Sb extending to cover is formed.

However, in the secondary molded product 110S of this modified example, the body-side wrap-around portion 110Sa extends substantially parallel to the inner surface 10Pa1 of the thick portion 10Pa (that is, similar to the inner surface 10Sa1 of the above embodiment). It has an inner surface 110Sa1 and a second inner surface 110Sa2 formed stepwise on the rear side of the lens with respect to the first inner surface 110Sa1.

The covering portion 110Sb of this modified example has the same shape as the covering portion 10Sb of the above-described embodiment, and the tip surface 110Sb1 thereof also has the same shape as the tip surface 10Sb1 of the covering portion 10Sb of the above-described embodiment. there is

A stepped portion between the first inner surface 110Sa1 and the second inner surface 110Sa2 is also formed of an inclined surface 110Sc having substantially the same shape as the tip surface 110Sb1 of the covering portion 110Sb.

Even when the configuration of this modified example is adopted, the same effects as those of the above-described embodiment can be obtained.

In addition, by adopting the configuration of this modified example, it is possible to further improve the ability to fill the covering portion 110Sb with the molten resin when molding the secondary molded product 110S.

Next, the 2nd modification of the said embodiment is demonstrated.

FIG. 7(b) is a view similar to FIG. 4(a), showing a main part of the two-color molded lens according to this modified example.

As shown in FIG. 7B, the basic configuration of this modification is the same as that of the above embodiment, but the configuration of the secondary molded product 210S is partially different from that of the above embodiment.

That is, also in this modification, the main body side wrapping portion 210Sa of the secondary molded product 210S extends from the joint surface 10b1 with the primary molded product 10P along the inner surface 10Pa1 of the thick portion 10Pa to the primary molded product 10P. A covering portion 210Sb extending so as to cover is formed.

However, the secondary molded product 210S of this modified example is formed so that the inner surface 210Sa1 of the main body-side wrap-around portion 210Sa extends in a direction inclined rearward of the lens toward the lens peripheral wall portion 14 side.

The covering portion 210Sb of this modified example has the same shape as the covering portion 10Sb of the above embodiment, and the tip surface 210Sb1 thereof also has the same shape as the tip surface 10Sb1 of the covering portion 10Sb of the above embodiment. there is

Even when the configuration of this modified example is employed, the same effects as those of the above-described embodiment can be obtained.

In addition, by adopting the configuration of this modified example, it is possible to further improve the ability to fill the covering portion 210Sb with the molten resin when molding the secondary molded product 210S.

It should be noted that the numerical values shown as specifications in the above-described embodiment and its modification are merely examples, and it goes without saying that these values may be set to different values as appropriate.

Moreover, the present invention is not limited to the configurations described in the above embodiments and modifications thereof, and configurations with various other modifications can be employed.

2 Worker 10 Two-color molded lens 10a Outer surface 10a1, 10b1 Joint surface 10b, 10Pa1, 10Sa1, 210Sa1 Inner surface 10c Connection position 10P Primary molded product 10Pa Thick part 10Pa2 Inner peripheral surface 10Pb Corner 10Pc Corner (second corner)
10S, 110S, 210S Secondary molded product 10Sa, 110Sa, 210Sa Main body side winding portion 10Sb, 110Sb, 210Sb Covering portion 10Sb1, 110Sb1, 210Sb1 Tip surface 12 Lens body portion 14 Lens peripheral wall portion 16 Outer peripheral flange portion 22 Hard coat film 24 Anti-fogging coating film 100 Mold for secondary molding 102, 104 Nozzle 106 Ultraviolet irradiation device 108 Heating furnace 110Sa1 First inner surface 110Sa2 Second inner surface 110Sc Slope C, Cb Space for secondary molding F Pressing force P1 Hard coat paint P2 Anti-fog paint RA, RB Corner R
Rs Molten resin T Covering thickness W Covering width θ1 Included angle θ2 Inclination angle

Claims (8)

A two-color molded lens comprising a primary molded product made of transparent resin and a secondary molded product made of opaque resin. A two-color molded lens having a rising lens peripheral wall portion and an anti-fogging coating film formed on the inner surface,
The primary molded product is formed so as to extend from the lens main body portion to the lens peripheral wall portion along the outer surface of the two-color molded lens,
The secondary molded product is formed so as to extend from the lens peripheral wall portion to the lens body portion along the inner surface of the two-color molded lens,
The joint surface between the inner peripheral end surface of the primary molded product and the outer peripheral end surface of the secondary molded product on the inner surface side of the two-color molded lens is located in the lens body portion from the outer surface side of the two-color molded lens. formed to extend to the inner surface of the two-color molded lens,
The secondary molded product is formed with a covering portion extending from the joint surface with the primary molded product along the inner surface of the primary molded product so as to cover the primary molded product. Characteristic two-color molded lens. 2. The two-color molded lens according to claim 1, wherein a hard coat film is formed on the outer surface of said two-color molded lens. 3. The two-color molded lens according to claim 1, wherein the covering portion is formed such that the tip end surface of the covering portion extends obliquely toward the inner surface of the primary molded product. . 4. The two-color molded lens according to claim 3, wherein the angle of inclination of the tip surface of the covering portion is set to 30 to 60 degrees. The corner R formed at the corner between the inner surface of the primary molded product and the joint surface in the primary molded product is set to a value of R 0.1 to 0.5 mm. A two-color molded lens according to any one of claims 1 to 4. 6. The two-color molded lens according to any one of claims 1 to 5, wherein an included angle between the cemented surface and the inner surface of the primary molded product is set to a value of 100° or more. In the primary molded product, the annular region along the bonding surface is a thick portion that is stepped up on the inner surface side of the two-color molded lens with respect to the general region located on the inner peripheral side of the annular region. is formed and
7. A corner R of 0.2 mm or more is formed at a corner between the inner surface of the general area of the primary molded product and the inner peripheral surface of the thick portion. A two-color molded lens as described. A two-color molded lens comprising a primary molded product made of transparent resin and a secondary molded product made of opaque resin. A two-color molded lens having a rising lens peripheral wall portion and an anti-fogging coating film formed on the inner surface,
The primary molded product is formed so as to extend from the lens main body portion to the lens peripheral wall portion along the outer surface of the two-color molded lens,
The secondary molded product is formed so as to extend from the lens peripheral wall portion to the lens body portion along the inner surface of the two-color molded lens,
The joint surface between the inner peripheral end surface of the primary molded product and the outer peripheral end surface of the secondary molded product on the inner surface side of the two-color molded lens is located in the lens body portion from the outer surface side of the two-color molded lens. formed to extend to the inner surface of the two-color molded lens,
In the primary molded product, the annular region along the bonding surface is a thick portion that is stepped up on the inner surface side of the two-color molded lens with respect to the general region located on the inner peripheral side of the annular region. is formed and
A two-color molded lens, wherein a corner R of 0.2 mm or more is formed at a corner between the inner surface of the general region of the primary molded product and the inner peripheral surface of the thick portion.

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