JP7399715B2 - injection molded products - Google Patents

Description

The present invention relates to an injection molded product, and particularly to an injection molded product in which a narrow space is formed between continuous partition walls.

Patent Document 1 discloses a combination lamp for a vehicle that includes a tail lamp, a stop lamp, and a turn signal lamp. A first light chamber having reflectors for tail lamps and stop lamps and a second light chamber housing a turn signal lamp unit are integrally molded as a lamp body of a vehicle lamp.

JP2002-279808

However, because both light chambers are integrally molded very close together, the space formed by the reflector of the tail lamp and stop lamp and the bulkhead of the turn signal lamp that is continuously folded back is extremely narrow. It has become a thing. In the molding die, it is not possible to install a cooling circuit in this narrow portion, and there is a problem in that sink marks (stripe patterns) occur on the reflector due to insufficient cooling.

This case was made with this in mind, and its purpose is to produce an injection molded product that, like the above-mentioned reflector, has a designed part with a predetermined shape and a non-designed part such as a partition wall adjacent to the designed part across a narrow space. The purpose is to suppress the occurrence of sink marks on products.

In order to solve the above problem, an injection molded product according to an aspect of the present invention is provided with a design part having a predetermined shape recessed on the back surface and configuring a desired appearance or function, and a design part that is continuous from the periphery of the design part. By being folded back, the non-design part adjacent to the design part across the narrow space is provided with an opening that communicates with the narrow space.

According to this aspect, in the molding die, this opening becomes a joint between the cavity side die and the core side die. Since the opening communicates with the narrow space, a joint surface is provided on the molding mold protrusion corresponding to the narrow space. The molding mold convex part has an elongated shape reflecting the narrow space between the design part and the non-design part folded back. It is not possible to install a cooling circuit to cool the mold in the elongated part, and with conventional designs without openings, heat tends to accumulate in the mold, causing insufficient cooling of the mold. By providing an opening in the molded product, a joint is provided in the molding mold convex part, and the temperature of the elongated molding mold convex part can be transmitted to the other mold via the joint part. can. In addition, since a cooling circuit can be provided near the other mold side that does not have a molding mold convexity, the cooling function extends to the molding mold convexity through the joint, and the molding mold convexity temperature can be lowered. By providing an opening in the molded product for the heat radiation mechanism of the mold, overheating of the mold (the convex portion of the mold) is prevented and the occurrence of sink marks is suppressed.

In one embodiment, the opening has a substantially rectangular shape with two opposing sides, and the opening has a thickness direction opposite to the stepped portion of the non-design portion. The structure is such that it is offset from the

According to this aspect, the opening having such a shape is formed as a so-called cut-off in the molding die. Normally, the opening is an undercut, but by forming the opening in this way, complicated treatments and processes such as split molds are not required, and molding can be performed easily.

Further, in one embodiment, the opening is folded back from the designed portion and is formed near a boundary with the designed portion.

According to this aspect, the tip of the convex part of the mold corresponding to the folded part in the narrow space is the part of the mold where heat is most likely to accumulate, so the opening is placed near the boundary to cool this part. By forming this, the cooling effect can be enhanced.

Further, in one embodiment, the opening is configured to be formed in a difficult-to-see part that is shielded by the designed part when the designed part is viewed from the front, or in a non-visible part that is hidden by a blinding material.

According to this aspect, the opening can be provided in a location where it is difficult to be visually recognized, and the influence on appearance can be minimized.

Further, in one embodiment, the opening is formed in a vertical wall of the casing that is continuous with the design part and is open to the front.

According to this aspect, the design part is not obstructed and the influence on the housing can be minimized.

Further, in one embodiment, the designed portion and the non-designed portion are configured to approach each other toward the folded portion that is the boundary.

According to this aspect, the narrow space is configured to become narrower toward the folded part, and the corresponding molding mold convex part also has a tapered shape, and forming an opening in this is a cooling method for the molding mold. The effect will be very high.

Further, in one aspect, the designed part is a first lamp chamber having an open front surface from which the irradiation light of the housed first light source is emitted, and the non-designed part is arranged from the periphery of the first lamp chamber. The second light chamber has a continuously folded surface as a vertical wall and has an open front surface through which the irradiated light from the housed second light source is emitted, and the two light chambers are close to each other with the narrow space in between. It is molded as one piece. According to this aspect, in a combination lamp including a plurality of light sources such as a vehicle headlamp, two light chambers can be integrally molded, so the number of parts can be reduced, and molding costs and assembly man-hours can be reduced.

Further, the designed portion is an optical reflector that reflects light toward the front, and the non-designed portion is a bracket member or a lamp chamber that is continuously folded back from the end of the optical reflector and is erected. It was constructed so that it was a standing wall that formed.

The reflector, bracket, or light chamber can be integrally molded with less sink marks, reducing molding costs and assembly man-hours.

As is clear from the above description, according to the present invention, it is possible to suppress the occurrence of sink marks in an injection molded product that includes a designed portion having a predetermined shape and a partition wall that is close to the designed portion with a narrow space between them.

FIG. 1 is a front view of a vehicle headlamp including a bracket unit (injection molded product) according to a first embodiment. FIG. 3 is a longitudinal cross-sectional view of the vehicle lamp. FIG. 3 is a partial cross-sectional view illustrating an opening of the bracket unit according to the first embodiment. It is a mold of the bracket unit according to the first embodiment. It is a thermal state of the metal mold|die of the bracket unit based on 1st Embodiment. (A) shows a mold for a molded product without an opening as a conventional example, and (B) shows a mold of the present embodiment with an opening. FIG. 3 is a sectional view of a vehicle headlamp including a bracket unit (injection molded product) according to a second embodiment. FIG. 7 is a partial cross-sectional view illustrating an opening of a bracket unit according to a second embodiment. It is a metal mold|die and a molding method of the bracket unit based on 2nd Embodiment. FIG. 6 is an explanatory diagram for explaining the formation position of the opening of the bracket unit.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. The embodiments are illustrative rather than limiting the invention, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention. In each figure, each direction (Upward: Downward: Leftward: Rightward: Frontward: Backward = Up: Do: Le: Ri: Fr:Re). Further, the ratios of the thickness, width, and length of each member do not reflect the actual ratios, but are schematic representations of the configuration.

(First embodiment)
1 and 2 are front views of a vehicle headlamp 1 equipped with a bracket unit 10 which is an injection molded product according to a first embodiment of the present invention, and FIG. 2 is a front view taken along the line II-II in FIG. FIG.

The vehicle headlamp 1 includes a lamp body 2, a front cover 3, a low beam unit LU, a high beam unit HU, and a bracket unit 10. The lamp body 2 has an opening at the front. The front cover 3 is made of translucent resin, glass, or the like, and is attached to the opening of the lamp body 2.

The low beam unit LU and the high beam unit HU are arranged in a room formed by the lamp body 2 and the front cover 3, and are held by a bracket unit 10.

The low beam unit LU includes a projector-type optical unit Lo1 that includes a light source 21 that is a light emitting element, a reflector 22, and a projection lens 24.

As the light source 21, a semiconductor light emitting element such as an LED (Light Emitting Diode), an LD (Laser Diode), or an EL (Electro Luminescence) element, a light bulb, an incandescent lamp (halogen lamp), a discharge lamp (discharge lamp), etc. can be used. can.

The reflector 22 is configured to guide the light emitted from the light source 21 in a desired direction, and has a predetermined reflective surface 22a on its inner surface. The emitted light from the light source 21 is reflected forward by the reflective surface 22a of the reflector 22, and is emitted to the front of the vehicle via the projection lens 24, forming a desired light distribution. The projection lens 24 is fixed to the bracket unit 10 by a support member (not shown).

The low beam unit LU is a triple optical unit including an optical unit Lo1 and optical units Lo1 and Lo3 having the same configuration, and forms a low beam light distribution in front of the vehicle by the three optical units Lo1, Lo2, and Lo3. .

The high beam unit HU is a drawing unit that is configured to form a predetermined shape and light distribution using light emitted from the front.The high beam unit HU is a drawing unit that is configured to form a predetermined shape and light distribution using light emitted from the front. Light can be formed.

The high beam unit HU includes a laser light source 31, a scanning mechanism 32, a collimating lens 33 that condenses the light emitted from the laser light source 31 and makes it enter the scanning mechanism 32, a control device 34 that controls the scanning mechanism 32 and the laser light source 31, and A projection lens 35 is provided. These components are attached to the housing 36 by a support mechanism (not shown).

The scanning mechanism 32 has a reflection mirror 32a supported so as to be able to rotate incident light in biaxial directions, and forms a desired drawing pattern by scanning the reflected light while rotating the reflection mirror 32a. . The desired drawing pattern is emitted to the front of the vehicle via the projection lens 35 to form a desired light distribution pattern.

In this embodiment, the scanning mechanism 32 is employed as a variable light distribution device in the high beam unit HU, but it is also possible to form any pattern using any light, such as an LED array, pixel optical device, light deflection device light, etc. You may also use a device. Further, there is no problem even if a reflector-type optical unit, a projector-type optical unit, or the like that forms only a desired light distribution is used as the low beam unit LU and the high beam unit HU.

The extension reflector 5 is a blinding material that hides unnecessary parts. Mechanical parts and fixed parts of the low beam unit LU and high beam unit HU are hidden by the extension reflector 5.

(Bracket unit 10)
The bracket unit 10 will be explained in detail. FIG. 3 is a perspective view of a part of the bracket unit 10, in which the bracket unit 10 is cut out at a predetermined width centering on the line II-II in FIG. FIG. 3(A) is a rear top perspective view, and FIG. 3(B) is a front bottom perspective view.

As shown in FIGS. 2 and 3, the bracket unit 10 forms a light chamber RL for the low beam unit LU and a light chamber RH for the high beam unit HU. It is attached to the lamp body 2 by an aiming screw E. The optical axis of each unit is adjusted in the horizontal and vertical directions by rotating each aiming screw E.

In this embodiment, a part of the bracket unit 10 constitutes the reflector 22 of the low beam unit LU. Further, the high beam unit HU is installed inside a light chamber RH that is formed by using a partition wall 41a that is continuously folded back from the lower end of the reflector 22 as a vertical wall.

The light chamber RH is defined by a partition wall 41a, a partition wall 41b, etc. that are erected in front of the vertical portion 41c of the bracket unit 10. There are partition walls (not shown) also in the left and right directions of the vertical portion 41c. Hereinafter, when referring to a member that defines the lamp chamber RH, which is a front-opening bag portion, without specifying a particular part, it will simply be referred to as a partition wall 41.

The bracket unit 10 includes a reflector 22 (light chamber RL), a partition wall 41 defining the light chamber RH, and a bracket member for holding and fixing the low beam unit LU and the high beam unit HU, which are integrally molded. By providing one multifunctional component, the number of components can be reduced, and manufacturing and assembly costs can be reduced.

Here, since the partition wall 41a is continuously folded back from the lower end of the reflector 22 to the back surface, a narrow space SR1 is formed between the reflector 22 and the partition wall 41a on the back side of the bracket unit 10. is formed.

A step portion 43 is provided on the partition wall 41a, and an opening portion 42 communicating with the narrow space SR1 is formed in the step portion 43.

The opening 42 is provided in the partition wall 41a in a rectangular shape, but instead of being a through hole provided in a plane, the step 43 is used so that the thickness direction of one side of the rectangle is opposite to the thickness direction of the other side. It is configured to be oriented. That is, the sides 42a, 42b, 42c, and 42d forming a rectangular shape on the lower surface 41aa of the partition wall 41a form the outer shape of the opening 42, but the sides 42a, 42b, 42c, and 42d forming a rectangular shape with the lower surface 41aa as a reference and the ridgeline of the stepped portion 43 as one side. The thickness direction of 42a is downward, and the thickness direction of the remaining three sides 42b, 42c, and 42d is downward.

(Mold of the first embodiment: cut-off mold)
A method of forming the bracket unit 10 having the above shape will be explained. FIG. 4 shows a mold 50 of the bracket unit 10. FIG. 2 is a cutaway view taken at a position corresponding to line II-II in FIG. 1. FIG.

As shown in FIG. 4, the mold 50 includes a cavity side mold 60 and a core side mold 70. The cavity side mold 60 and the core side mold 70 are arranged facing each other and are clamped. In the clamped state, a molding space MS1 corresponding to the shape of the bracket unit 10 is defined inside the mold 50. A resin member heated to a predetermined melting temperature is injected into this molding space MS1, and the bracket unit 10 is molded.

A convex portion 71 corresponding to the narrow space SR1 is provided on the opposing surface (molding surface) of the core side mold 70. In this embodiment, the surface 71a forming part of the convex portion 71 and the surface 60a forming part of the molding surface of the cavity side mold 60 are configured to be joined at a portion. An opening 42 is formed in the bracket unit 10 by the joint 51 between the two in a so-called cut-off shape.

The mold 50 is provided with a cooling circuit 80 for cooling and solidifying the injected resin member. The cooling circuit 80 is configured to flow a cooling fluid such as water through cooling holes provided in the cavity side mold 60 and the core side mold 70, and fills the molding space MS1 by cooling the mold 50. The resulting resin member is indirectly cooled and solidified. The cooling circuit 80 is provided as appropriate to make the temperature distribution of the molding surfaces of the cavity side mold 60 and the core side mold 70 uniform.

(effect)
The effects of this embodiment in which the bracket unit 10 is provided with the opening 42 will be explained using FIG. 5. FIG. 5(A) shows the temperature distribution of a mold 950 of a molded product in which no opening is provided in the partition wall that is continuously folded back from the reflector as a conventional example, and FIG. The temperature distribution of the mold 50 of the bracket unit 10 is shown.

As shown in FIG. 5(A), the mold 950 includes a cavity side mold 960 and a core side mold 970. A convex portion 971 corresponding to the narrow space formed between the reflector portion and the partition wall continuous thereto is provided on the core side mold 970. The convex portion 971 does not have sufficient thickness or width to provide a cooling hole, and also does not have sufficient space to arrange the cooling circuit 80 nearby, so the cooling circuit 80 cannot be provided therein either. When the melted resin member is injected, the convex portion 971 becomes extremely hot because it is surrounded by the high temperature resin member. Since the cooling circuit 80 cannot be provided in the convex portion 971, the temperature of the mold 950 cannot be lowered, and sink marks (stripe patterns) are generated in the molded product due to overheating. Since the narrow space is formed near the back of the reflector, if sink marks occur on the reflector, problems will occur in light distribution. In order to solve this problem, an opening 42 is provided in the bracket unit 10 in this embodiment.

As shown in FIG. 5(B), the reflector 22 and the partition wall 41a of the bracket unit 10 are provided continuously and very close to each other, so that the core side corresponding to the narrow space SR1 formed between them The convex portion 71 of the mold 70 also has a very small shape. Therefore, like the conventional product, the convex portion 71 does not have sufficient thickness or width to provide cooling holes, and the cooling circuit 80 cannot be provided.

However, unlike the conventional mold 950, the mold 50 is provided with a joint 51 in order to form the opening 42 in the molded product. Since the convex part 71 of the cavity side mold 60 and the core side mold 70 are in direct contact with each other at the joint part 51, the heat of the convex part 71 moves to the core side mold 70 (see the white arrow in the figure). . Since the mold 50 is made of a metal member, it has high thermal conductivity. 51.

As a result, the temperature of the convex portion 71 is lowered, and the temperature of the entire mold 50 is lowered and kept uniform, so that overheating does not occur and the occurrence of sink marks on the reflector 22 can be suppressed. Metal vapor deposition is performed on the reflective surface 22a of the reflector 22 after injection molding.

The convex portion 71 has a tapered shape reflecting the shape of the reflector 22, and since heat is trapped at the tip thereof (see FIG. 5(A)), the opening portion 42 is provided near the boundary where the reflector 22 is folded back. This is preferable since it has a high cooling effect.

In addition, it is necessary to wait for the resin component to cool and completely solidify before opening the mold, but since the time required to cool the molten resin component takes up a large proportion of the molding cycle, conventional products Since it is necessary to wait until the heat of the convex portion 71 of 950 is sufficiently lowered, the molding time is long and productivity is low. Providing the opening 42 in the bracket unit 10, that is, providing the joint 51 in the mold 50 for molding the bracket unit 10, increases the cooling rate of the mold 50, shortens molding time, and improves productivity. has improved.

(Second embodiment)
Next, a second embodiment will be described. FIG. 6 is a sectional view of a vehicle headlamp 101 including a bracket unit 110 which is an injection molded product according to a second embodiment. FIG. 7 is a partial perspective view of the bracket unit 110. 7, similarly to FIG. 3, the bracket unit 110 is cut out at a predetermined width centering on the line II-II in FIG. FIG. 7(A) is a rear upper perspective view, and FIG. 7(B) is a front lower perspective view. Components that are equivalent to those in the first embodiment are designated by the same reference numerals, and the description thereof will be omitted.

The vehicle headlamp 101 has the same configuration as the vehicle headlamp 1 except that the form of the bracket unit 110 is different.

The bracket unit 110 includes a partition wall 141a that is continuously folded back from the lower end of the reflector 22 that opens toward the front. The partition wall 141a is configured as a vertical wall that defines the lamp room RH.

Since the reflector 22 and the partition wall 141a are provided very close to each other, a narrow space SR2 is formed between them.

Here, similar to the first embodiment, the partition wall 141a has an opening 142 that communicates with the narrow space SR2, but unlike the first embodiment, the partition wall 141a is not provided with a stepped portion. Therefore, the opening 142 is configured as a through hole provided in the flat partition wall 141a.

(Mold of second embodiment: slide mold)
A method of forming the bracket unit 110 having the above shape will be explained. FIG. 8 shows a mold 150 of the bracket unit 110.

As shown in FIG. 8, the mold 150 includes a cavity side mold 160 having a slide member 161 and a core side mold 170. The slide member 161 is provided as a nest of the cavity-side mold 160, and is configured to be slidable in the direction of arrow DR1 (vertical direction) with respect to the cavity-side mold 160, which is the main body. The slide member 161 is provided to form the opening 142 in the bracket unit 110.

Furthermore, a convex portion 171 corresponding to the narrow space SR2 is provided on the molding surface of the core side mold 170.

When the cavity side mold 160 and the core side mold 170 are clamped, the slide member 161 moves upward and is held with its tip end in contact with the protrusion 171 of the core side mold 170. Ru. A molding space MS2 corresponding to the shape of the bracket unit 110 is defined inside the mold 150, a resin member heated to a predetermined melting temperature is injected into this molding space MS2, and the bracket unit 110 is molded. Ru.

As mentioned above, the convex portion 171 corresponding to the narrow space SR2 is surrounded by the molding space MS2 into which the resin member heated to the melting temperature is poured, and has a structure that tends to trap heat, but it has a tapered and elongated shape. Therefore, the cooling circuit 80 cannot be provided.

In this embodiment, a slide mold is used to bring the slide member 161 into contact with the convex portion 171, thereby transmitting heat from the convex portion 171 from the contact portion 172 (in the direction of the white arrow in the figure). , the temperature of the convex portion 171 is lowered. The slide member 161 and the cavity side mold 160 are made of metal members, and the convex portion 171 cools the slide member 161 by the cooling circuit 80 of the cavity side mold 160 disposed near the slide member 161 and the contact portion 172. cooled through.

After the mold 150 is sufficiently cooled, the slide member 161 moves downward and separates from the convex portion 171 and lowers to a position where it does not contact the resin member, and the mold 150 is opened and the resin molded product ( The bracket unit 110) is removed.

If the resin molded product is large and the opening 142 can be made large, the cooling circuit 80 may be provided in the slide member 161. Further, the cooling effect may be enhanced by providing a plurality of openings 142 in the bracket unit 110 and using a plurality of slide members 161 in the mold 150.

In this embodiment, a resin molded product is used, which consists of a reflector that forms a reflective surface with a concave shape on the back, and a bulkhead of the light chamber that is continuously folded back to the back. The present invention can also be applied to integrally molded products such as a parabolic reflector and its bracket member, or a parabolic reflector and its bracket member.

A design part that has a predetermined shape such as a reflector and provides a desired appearance or function must be prevented from producing sink marks and must not have an opening. By providing an opening in a non-design part that is continuously folded back from the periphery of the design part, such as a bracket member or a standing wall, it is possible to prevent sink marks from occurring in the design part. It can be suppressed.

(Modified example)
The opening for heat radiation of the molding die, which is provided in the non-design part of the integrally molded product having the above structure, is preferably a part that is difficult to see from the user or a non-visible part that is hidden by a blinding material. As an example, FIG. 9 shows the relationship between the mounting locations of the vehicle lamps LP, LP' and the user's line of sight, and this will be explained.

The vehicle lamp LP is mounted on the back of the vehicle V, and includes a reflector unit 90 in which a parabolic reflector 91 and a bracket member 92 thereof are integrally molded inside the lamp chamber. Similar to the embodiment described above, the bracket member 92 of the reflector unit 90 is configured by being folded back from the periphery of the parabolic reflector 91, and an opening 93 is formed in the bracket member 92.

The vehicle lamp LP is mounted on the upper rear surface of the vehicle V (for example, a high mount stop lamp), and the bracket member 92 is constructed on the upper part of the parabolic reflector 91. When the vehicle lamp LP is mounted on the vehicle V, even if the user directly faces the vehicle lamp LP and checks it, the opening 93 provided in the bracket member 92 is hidden by the parabolic reflector 91. and is not visible.

In addition, when a vehicle light LP' having the same configuration as the vehicle light LP is mounted at a relatively low position of the vehicle V (for example, as a back lamp), contrary to the above, it should be mounted at the bottom of the parabolic reflector 91'. By providing the bracket member 92' and forming the opening 93' therein, the opening 93' can be shielded by the parabolic reflector 91'.

In this way, by providing an opening in a location that is difficult for the user to see when viewing the molded product from the front during normal use, the impact on appearance caused by the opening can be minimized. .

Although preferred embodiments and modified examples of the present invention have been described above, the above-mentioned embodiments are only examples of the present invention, and these can be combined based on the knowledge of those skilled in the art, and such forms are also covered by the present invention. within the scope of the invention.

10, 110: Bracket unit 22: Reflector 22a: Reflective surface 41a, 141a: Partition wall 42, 142: Opening portion 42a, 42b, 42c, 42d: Side 43: Step portion RH, RL: Light chamber SR1, SR2: Narrow space

Claims (8)

It has a design part that has a predetermined shape that is concave on the back and has a desired appearance or function, and is continuously folded back from the periphery of the design part, so that it can be placed adjacent to the design part across a narrow space. The design part is provided with an opening that communicates with the narrow space.
An injection molded product characterized by: The outer shape of the opening is a rectangular shape having two opposing sides,
The opening portion is formed in the stepped portion of the non-design portion so that the thickness directions of the two opposing sides are offset in opposite directions.
The injection molded article according to claim 1, characterized in that: The opening portion is folded back from the designed portion and is formed near a boundary with the designed portion.
The injection molded article according to claim 1 or 2, characterized in that: The opening is formed in a difficult-to-see part that is shielded by the designed part when the designed part is viewed from the front, or in a non-visible part that is hidden by a blinding material.
The injection molded article according to any one of claims 1 to 3, characterized in that: The opening portion is formed in a vertical wall portion of the casing that is continuous with the design portion and is open to the front.
The injection molded product according to any one of claims 1 to 4, characterized in that: The designed portion and the non-designed portion are configured to become closer toward the folded portion that is the boundary;
The injection molded product according to any one of claims 1 to 5, characterized in that: The design part is a first lamp chamber with an open front surface from which the irradiation light of the housed first light source is emitted;
The non-design portion is a second light chamber having a surface continuously folded back from the periphery of the first light chamber as a vertical wall, and having an open front surface from which the irradiation light of the accommodated second light source is emitted. The injection molded product according to any one of claims 1 to 6, wherein the two lamp chambers are integrally molded adjacent to each other with the narrow space in between. The design part is an optical reflector that reflects light toward the front,
The non-design part is a bracket member that is continuously folded back from the end of the optical reflector and is erected, or a standing wall that forms a light chamber.
The injection molded product according to any one of claims 1 to 6, characterized in that: