WO2015162822A1 - 通気部材および通気装置 - Google Patents
通気部材および通気装置 Download PDFInfo
- Publication number
- WO2015162822A1 WO2015162822A1 PCT/JP2014/083143 JP2014083143W WO2015162822A1 WO 2015162822 A1 WO2015162822 A1 WO 2015162822A1 JP 2014083143 W JP2014083143 W JP 2014083143W WO 2015162822 A1 WO2015162822 A1 WO 2015162822A1
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- WIPO (PCT)
- Prior art keywords
- ventilation member
- hole diameter
- ventilation
- diameter structure
- water vapor
- Prior art date
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V31/00—Gas-tight or water-tight arrangements
- F21V31/03—Gas-tight or water-tight arrangements with provision for venting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/26—Drying gases or vapours
- B01D53/268—Drying gases or vapours by diffusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
- B60Q1/00—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
- B60Q1/0005—Devices preventing the lights from becoming dirty or damaged, e.g. protection grids or cleaning by air flow
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
- F21S45/30—Ventilation or drainage of lighting devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V31/00—Gas-tight or water-tight arrangements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/80—Water
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
- B01D2258/06—Polluted air
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
- B01D53/228—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion characterised by specific membranes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
- F21W2107/00—Use or application of lighting devices on or in particular types of vehicles
Definitions
- the present invention relates to a ventilation member and a ventilation device.
- a ventilation opening is provided in the casing for the purpose of preventing deformation or rupture of the casing due to a temperature difference between the inside and outside of the casing.
- a ventilation member for preventing water and dust from entering the housing is attached to the ventilation opening.
- a filter member made of a microporous film manufactured by a stretching method, an extraction method, or the like is provided in a ventilation opening formed in a housing of a vehicle lamp, so that the waterproof property of the housing is improved. It is described that the dust resistance is improved.
- the microporous membrane for example, the use of a porous membrane made of polytetrafluoroethylene having a pore diameter of 0.01 to 10 ⁇ m is described.
- An object of this invention is to provide the ventilation member and ventilation apparatus which can accelerate
- the ventilation member 20 to which the present invention is applied is a porous ventilation member 20 that discharges water vapor in the closed lamp housing 8, and is in the lamp housing of liquid water and contaminants.
- a small hole diameter structure 21 that forms a flow path for discharging water vapor from the inside of the lamp housing 8 to the outside, and the small hole diameter structure 21 is larger in diameter than the small hole diameter structure 21.
- a large hole diameter structure 22 provided in communication therewith.
- the small hole diameter structure 21 may be characterized in that the hole diameter D1 is not less than 0.5 ⁇ m and not more than 50 ⁇ m.
- the large pore structure 22 may be characterized in that the pore diameter D2 is 5 ⁇ m or more and 100 ⁇ m or less.
- the ventilation member 20 to which the present invention is applied is a porous ventilation member 20 that ventilates the inside of the closed casing 8 and the outside. It has a small hole diameter structure 21 that prevents intrusion into the housing 8 and allows water vapor to pass from the inside of the housing 8 to the outside, and a large hole diameter structure 22 having a larger diameter than the small hole diameter structure 21, and is self-supporting as a shape. It is formed as a molded product having a thickness having properties.
- the thickness t1 of the ventilation member 20 may be 10 mm or less.
- the ventilation member 20 may have a thickness t1 of 1 mm or more.
- the ventilation member 20 is a concavo-convex molded product, and the concavo-convex shape increases the surface area and widens the water vapor transmission area.
- the ventilation device to which the present invention is applied is a ventilation device for discharging water vapor in the closed lamp 1 and is closed with at least one ventilation opening 9.
- the vent housing 20 includes a lamp housing 2 and a vent member 20 provided in the vent opening 9.
- the vent member 20 communicates with the small hole diameter structure 21 having a hole diameter of 0.5 ⁇ m or more and 50 ⁇ m or less, and the small hole diameter structure 21.
- a large-pore structure 22 having a larger diameter than the small-pore structure 21.
- (A)-(b) is a figure for demonstrating the structure of the ventilation
- (A)-(b) is the figure which showed the other form of the ventilation member.
- FIG. 1 is a diagram showing an overall configuration of a vehicle lamp 1 to which the present exemplary embodiment is applied.
- the vehicle lamp 1 to which the present embodiment is applied is used as, for example, a head lamp, rear lamp, brake lamp, fog lamp, direction indicator lamp, travel lamp, parking lamp, etc. of various vehicles represented by automobiles.
- FIG. 1 shows an example of these lamps.
- a vehicle lamp 1 shown in FIG. 1 includes a housing 2 that protects vehicle electrical components and the like, and a lens 3 that is attached to the housing 2 and irradiates light at an appropriate angle, such as concentrating light in front of the lamp. And.
- the casing 2 and the lens 3 constitute a closed casing (inside the lamp casing) 8 of the vehicular lamp 1, and the waterproofness and dustproofness of the electrical components in the casing 8 are enhanced.
- the inside 8 of the housing is not completely sealed and can be ventilated through the vent opening 9.
- the ventilation opening 9 is configured by a cylindrical convex portion 9 a that protrudes outward from the housing 2.
- the casing 8 includes a bulb 4 that emits light and a reflector 5 that reflects the light emitted from the bulb 4 in the lateral direction and rearward toward the front as one of the electrical components.
- the vehicular lamp 1 serves as one of ventilation means to deliver air inside and outside the lamp, and in particular, it is possible to release the water vapor in the housing 8 to the outside of the vehicular lamp 1.
- a ventilation unit 10 is provided. And the vehicle lamp 1 which has this ventilation unit 10 can be grasped
- FIGS. 1 and 2 (a) to 2 (b) are diagrams for explaining the configuration of the ventilation unit 10 to which the present embodiment is applied.
- FIG. 2 (a) is a perspective view of the ventilation unit 10.
- FIG. 2B is a cross-sectional view of the ventilation unit 10 cut along the ventilation direction of the ventilation unit 10.
- the ventilation unit 10 of the present embodiment provides ventilation between the inside 8 of the vehicle lamp 1 and the outside of the vehicle lamp 1.
- the support member 11 of the present embodiment has, for example, a cylindrical shape as a whole, and a columnar through hole is formed inside. Referring also to FIG. 1 described above, the support member 11 is attached by fitting one end of the support member 11 to the outer periphery of the convex portion 9a constituting the ventilation opening 9 formed in the vehicle lamp 1. A continuous ventilation path is formed from the ventilation opening 9.
- the support member 11 supports the ventilation member 20 on the inner periphery of the through hole. In other words, the support member 11 of the present embodiment is in a state where the ventilation path is blocked by the ventilation member 20.
- the attachment method of the ventilation member 20 with respect to the support member 11 is not specifically limited, For example, you may attach by fitting methods, such as a welding method and a snap fit, and you may attach by an adhesive tape, an adhesive agent, etc.
- the inner diameter of the support member 11 (that is, the diameter of the ventilation path by the support member 11) is not particularly limited, but is 10 mm to 70 mm, for example, depending on the size of the vehicle lamp 1 to which the ventilation unit 10 is attached. Can be about.
- the inner diameter of the support member 11 is excessively small, the ventilation area in the ventilation unit 10 is small, so that it is difficult for water vapor to pass from the inside 8 of the housing of the vehicle lamp 1 to the outside, and the vehicle lamp 1 is clouded. The effect of suppressing this tends to be small.
- the ventilation member 20 of the present embodiment has, for example, a disk shape as a whole. That is, the ventilation member 20 of the present embodiment has two opposing circular planes 20A and 20B, and side surfaces that connect the planes 20A and 20B.
- the ventilation member 20 has one plane (in this example, the plane 20A) facing the inside 8 of the casing of the vehicle lamp 1 in a state where the ventilation unit 10 is attached to the ventilation opening 9 of the vehicle lamp 1.
- the other plane in this example, the plane 20 ⁇ / b> B faces the outside of the vehicle lamp 1.
- the shape of the ventilation member 20 is not limited to the disk-like shape shown in FIG.
- the ventilation member 20 of the present embodiment is made of a porous resin. More specifically, the ventilation member 20 is made of a porous resin having an open cell structure in which a plurality of holes having different hole diameters (a small hole diameter structure 21 and a large hole diameter structure 22 described later; see FIG. 3) communicate with each other. .
- the ventilation member 20 conducts ventilation between the inside 8 of the vehicle lamp 1 and the outside of the vehicle lamp 1, and foreign matter such as dust or liquid water (liquid) is contained inside the housing 8 of the vehicle lamp 1. Water) etc. are suppressed.
- the ventilation member 20 suppresses the occurrence of fogging of the lens 3 by allowing the water vapor in the housing 8 to pass therethrough and discharging it to the outside of the vehicle lamp 1.
- Examples of the material of the ventilation member 20 include polybutylene terephthalate (PBT), polybutylene naphthalate, polyethylene, polystyrene, acrylonitrile-styrene copolymer resin (AS resin), acrylonitrile-butadiene-styrene copolymer resin (ABS resin), Thermoplastic resins such as polypropylene, polycarbonate and polyacetal can be used. Among these, it is preferable to use PBT from the viewpoint of the strength and heat resistance of the ventilation member 20.
- the ventilation member 20 of the present embodiment is a single product (ie, removed from the support member 11) and is a molded product that is self-supporting as a shape.
- the thickness t1 along the ventilation direction of the ventilation member 20 (hereinafter simply referred to as the thickness of the ventilation member 20) t1 is such a thickness that the ventilation member 20 is self-supporting as a shape.
- the “thickness that is self-supporting as a shape” means that the ventilation member 20 is not in the form of a film and can maintain a certain shape even when there is no frame such as the support member 11, for example. it can.
- the frame body is not deformed at all except for the frame body, and it means a certain thickness that can be handled as a single unit in the work such as mounting.
- this does not mean that the case of using a frame is not included.
- the shape can be further strengthened by using a frame.
- the ventilation member 20 of the present embodiment may have a water / oil repellent coating on its surface.
- a water / oil-repellent coating on the ventilation member 20
- adhesion of dust and the like containing oil to the ventilation member 20 is suppressed, and a decrease in the permeability of air and water vapor in the ventilation member 20 is suppressed.
- a known water / oil repellent treatment agent such as fluorine or silicone can be used.
- a fluorine-based water / oil repellent treatment agent having high water repellency and oil repellency.
- the fluorine-based water / oil repellent treatment agent is not particularly limited.
- a polymer having a perfluoroalkyl group can be preferably used.
- FIG. 3 is an enlarged cross-sectional view of the ventilation member 20 cut in the thickness direction (aeration direction), and is an enlarged view of a portion III in FIG.
- the ventilation member 20 of the present embodiment is made of a porous body in which a plurality of holes (small holes 21a, large holes 22a) having different hole diameters are formed.
- the ventilation member 20 includes a plurality of small hole diameter structures 21 and a plurality of large hole diameter structures 22 having a larger diameter than the small hole diameter structures 21.
- the small hole diameter structure 21 is configured by a wall surface 21 b surrounding the small hole 21 a formed in the ventilation member 20, and the large hole diameter structure 22 is formed by the wall surface 22 b surrounding the large hole 22 a formed in the ventilation member 20. Composed.
- each small hole diameter structure 21 and each large hole diameter structure 22 is a shape that can be regarded as almost granular, such as a spherical shape, an ellipsoid, a spindle, or a polygonal shape. If it is, it will not specifically limit.
- the ventilation member 20 of this Embodiment has the open-cell structure where the small hole diameter structure 21 and the large hole diameter structure 22 were mutually connected.
- the state in which the small hole diameter structure 21 and the large hole diameter structure 22 communicate with each other is a state in which water vapor, air, or the like can flow between the small hole diameter structure 21 and the large hole diameter structure 22.
- the small hole 21a surrounded by the small hole diameter structure 21 and the large hole 22a surrounded by the large hole diameter structure 22 are a continuous space.
- the ventilation member 20 of the present embodiment it is only necessary that at least some of the plurality of small hole diameter structures 21 and the plurality of large hole diameter structures 22 communicate with each other. In other words, not all the small hole diameter structures 21 need to communicate with the large hole diameter structure 22, and not all the large hole diameter structures 22 need to communicate with the small hole diameter structure 21. Further, in the ventilation member 20, as shown in FIG. 3, a plurality of large hole diameter structures 22 may be connected to one small hole diameter structure 21, and a plurality of small hole diameters may be connected to one large hole diameter structure 22. The structure 21 may be communicated. Furthermore, in the ventilation member 20, there may be a portion where a plurality of small hole diameter structures 21 communicate with each other, or a portion where a plurality of large hole diameter structures 22 communicate with each other.
- the small hole diameter structure 21 prevents entry of contaminants such as dust and liquid water (liquid water) into the housing 8 (see FIG. 1), and the housing 8 A flow path for discharging water vapor to the outside of the vehicle lamp 1 (see FIG. 1) is formed.
- the large hole diameter structure 22 is provided so as to communicate with the small hole diameter structure 21, so that water vapor is supplied from the inside 8 of the housing to the outside of the vehicle lamp 1 together with the small hole diameter structure 21.
- a flow path for discharging is formed.
- the large hole diameter structure 22 has a function of shortening the flow path formed by the small hole diameter structure 21 by communicating with the small hole diameter structure 21 and promoting the discharge of water vapor from the inside 8 of the housing to the outside of the vehicle lamp 1. .
- the flow path formed by the communication between the small hole diameter structure 21 and the large hole diameter structure 22 is from the one plane 20A side of the ventilation member 20 (see FIG. 2B) to the other plane 20B. It connects to the side (refer FIG.2 (b)). That is, in a state where the ventilation unit 10 is attached to the housing 2 of the vehicle lamp 1 (see FIG. 1), the inside 8 of the housing and the outside of the vehicle lamp 1 are separated by the small hole diameter structure 21 and the large hole diameter structure 22. They are connected via a formed flow path. Thereby, in a state where the ventilation unit 10 is attached to the vehicle lamp 1, air and water vapor can move between the inside 8 of the housing and the outside of the vehicle lamp 1 through the ventilation member 20.
- the thickness t1 (see FIG. 2B) of the ventilation member 20 varies depending on the material used as the ventilation member 20, the shape of the ventilation member 20, the object to which the ventilation member 20 is applied, and the like. It is preferable that it is the range of these.
- the thickness of the ventilation member 20 By setting the thickness of the ventilation member 20 to 1 mm or more, it is possible to secure a sufficiently long continuous bubble structure in which the small hole diameter structure 21 and the large hole diameter structure 22 communicate with each other. It becomes possible to promote the discharge of water vapor to the outside.
- the thickness t1 of the ventilation member 20 varies depending on the material used for the ventilation member 20, the shape of the ventilation member 20, the object to which the ventilation member 20 is applied, etc., but is preferably in the range of 10 mm or less, for example.
- the thickness t1 of the ventilation member 20 is thicker than 10 mm, the distance from the inside 8 of the housing to the outside of the vehicle lamp 1 (see FIG. 1) becomes long, so the time required for discharging water vapor to the outside of the vehicle lamp 1 Becomes longer. In this case, the time until the cloud of the lens 3 (see FIG. 1) of the vehicle lamp 1 becomes clear tends to be long.
- the thickness t1 of the ventilation member 20 can maintain the strength as a molded product, suppresses fogging of the vehicle lamp 1 through water vapor, and quickly eliminates fogging when fogging occurs.
- the thickness is not limited to the above range.
- the hole diameter of the small hole diameter structure 21 is the first hole diameter D1
- the hole diameter of the large hole diameter structure 22 is the second hole diameter D2, as described above, as compared with the first hole diameter D1.
- the second hole diameter D2 is large (D1 ⁇ D2).
- the first hole diameter D1 is preferably smaller than the second hole diameter D2 and in the range of not less than 0.5 ⁇ m and not more than 50 ⁇ m.
- the 1st hole diameter D1 is less than 0.5 micrometer, it becomes difficult to permeate
- the 2nd hole diameter D2 is larger than the 1st hole diameter D1, and is the range of 5 micrometers or more and 100 micrometers or less.
- the 2nd hole diameter D2 is less than 5 micrometers, the effect of promoting discharge
- the 2nd hole diameter D2 is 100 micrometers or more, there exists a possibility that the intensity
- the second hole diameter D2 is preferably twice or more the first hole diameter D1, although it depends on the size of the first hole diameter D1 and the second hole diameter D2. It is preferable that it is twice or more. If the second hole diameter D2 is less than twice the first hole diameter D1, the difference in hole diameter between the small hole diameter structure 21 and the large hole diameter structure 22 is small. The pump effect described later due to the foam structure becomes insufficient, and it may be difficult to promote the discharge of water vapor.
- the first hole diameter D1 and the second hole diameter D2 can be measured, for example, by the following method. That is, a scanning electron microscope (SEM) photograph of the cross section of the ventilation member 20 is taken, and the area of the holes existing in a predetermined range (for example, a square range with one side of 200 ⁇ m) in the SEM photograph is commercially available. Analyzing with image processing software. When a plurality of holes communicate with each other, the area of the holes is analyzed on the assumption that the respective holes do not communicate with each other. Then, based on the analyzed hole area, the diameter of each hole in terms of a circle and its distribution (number distribution) are obtained.
- SEM scanning electron microscope
- the present embodiment there are a small hole 21 a corresponding to the small hole diameter structure 21 and a large hole 22 a corresponding to the large hole diameter structure 22 as the holes formed in the ventilation member 20.
- a small hole 21 a corresponding to the small hole diameter structure 21
- a large hole 22 a corresponding to the large hole diameter structure 22 as the holes formed in the ventilation member 20.
- the smaller value can be the first hole diameter D1
- the larger value can be the second hole diameter D2.
- the vehicle lamp 1 such as an automobile lamp
- there is a problem of dew condensation or cloudiness of the lens 3 caused by moisture in the housing 8 (a phenomenon in which the lens 3 becomes cloudy white due to fine water droplets).
- the casing 2 of the vehicle lamp 1 when the casing 2 of the vehicle lamp 1 is sealed, it becomes difficult to let the intruding moisture (humidity) escape to the outside of the vehicle lamp 1.
- the housing 2 of the vehicle lamp 1 is sealed, the housing 2 may be damaged when the inside of the housing 8 becomes hot due to heat generated by the bulb 4 of the vehicle lamp 1 and the air in the housing 8 expands. There is.
- the housing 2 of the vehicle lamp 1 is not sealed, but the vehicle lamp 1 is provided with a ventilation opening 9 for venting the outside, and the liquid water to the inside 8 of the housing is provided in the ventilation opening 9.
- a ventilation member is provided to prevent intrusion of contaminants.
- the housing 8 of the vehicle lamp 1 for example, when the outside air temperature is low or the humidity in the housing 8 is high, condensation occurs in the housing 8 of the vehicle lamp 1, and the lens 3 is likely to be clouded. It has become.
- the transfer of water vapor between the interior 8 of the vehicle lamp 1 and the ambient air outside the vehicle lamp 1 is promoted, and the vehicle is quickly It is preferable to keep the temperature and humidity environment inside and outside the lamp 1 constant and to reduce the humidity inside the housing 8.
- a porous body having an open cell structure in which the small hole diameter structure 21 and the large hole diameter structure 22 are communicated is used as the ventilation member 20 provided in the ventilation opening 9 of the vehicular lamp 1.
- ramp 1 for vehicles can be suppressed, and even if it is a case where fogging generate
- the flow path formed in the ventilation member 20 when water vapor moves from the large pore diameter structure 22 to the small pore diameter structure 21, the flow area of the water vapor is fast because the flow passage area becomes narrow in the small pore diameter structure 21. Become. As a result, water vapor is pushed out from the small hole diameter structure 21 toward the large hole diameter structure 22 communicating further downstream (outside of the vehicle lamp 1) (pump effect). As a result, in the ventilation member 20 of the present embodiment in which the flow path of water vapor is formed by communication between the small hole diameter structure 21 and the large hole diameter structure 22, for example, the flow path of water vapor is formed by a plurality of holes having substantially uniform hole diameters.
- the permeation of water vapor in the ventilation member 20 is promoted. And it becomes possible to discharge
- the plurality of small hole diameter structures 21 and the large hole diameter structure 22 communicate with each other so that the water vapor transmission path is connected in a mesh shape. ing.
- steam is formed in the ventilation member 20 more.
- water vapor is more easily transmitted from the inside 8 of the housing to the outside of the lamp 1, and the water vapor can be discharged from the inside of the housing 8 to the outside of the vehicle lamp 1 more quickly.
- the vent member 20 is not limited to the disk shape shown in FIG. 2 as long as the vent member 20 is a molded body having a continuous bubble structure in which the small hole diameter structure 21 and the large hole diameter structure 22 communicate with each other. It can be appropriately selected according to the shape of the vehicle lamp 1 and the like.
- the shape of the ventilation member 20 may be a polygonal column shape such as a quadrangular column or a spherical shape.
- the shape of the support member 11 that supports the ventilation member 20 is not limited to the cylindrical shape shown in FIG. 2, and can be appropriately selected according to the shape of the ventilation member 20 and the shape of the vehicle lamp 1.
- FIG. 4 (a) is a perspective view of the ventilation member 20, and FIG. FIG. 4 is a sectional view taken along the line IVB-IVB in FIG.
- the ventilation member 20 of the present embodiment protrudes from the attachment portion 31 that can be attached to the ventilation opening 9 of the vehicle lamp 1, and the like.
- a plurality of mountain-shaped protrusions 32 are formed.
- the entire ventilation member 20 including the attachment portion 31 and the mountain-shaped protrusion 32 has the above-described small hole diameter structure 21 (see FIG. 3) and large hole diameter structure 22 (see FIG. 3). It is comprised from the porous body which has the open-cell structure which communicated.
- the ventilation member 20 of the present embodiment has both the front surface (upper side in FIG. 4 (b)) and the rear surface (lower side in FIG. 4 (b)) by forming the mountain-shaped protrusion 32. Compared with the case where it is an uneven surface and the mountain-shaped protrusion 32 is not formed, the surface area is large.
- the ventilation member 20 When the ventilation member 20 is attached to the ventilation opening 9 of the vehicle lamp 1, the uneven surface formed by the mountain-shaped protrusions 32 on the inside 8 of the vehicle lamp 1 and outside the vehicle lamp 1. Are designed to face each other. Thereby, compared with the case where this structure is not employ
- the ventilation member 20 shown in FIGS. 4 (a) to 4 (b) has a thickness that is self-supporting as a shape without using other members (the above-mentioned support member 11 or the like; see FIG. 2). have.
- the ventilation member 20 of this Embodiment can attach the attachment part 31 directly to the ventilation opening 9 etc. of the lamp 1 for vehicles, without passing through another member. Thereby, compared with the case where this structure is not employ
- the method of attaching the ventilation member 20 to the ventilation opening 9 is not particularly limited.
- the ventilation member 20 may be attached by a fitting method such as a welding method or a snap fit, or may be attached by an adhesive tape or an adhesive.
- the manufacturing method of the ventilation member 20 is demonstrated.
- a method for manufacturing the ventilation member 20 by a so-called “extraction method” will be described.
- the manufacturing method by the extraction method of the ventilation member 20 is a mixing step of mixing a resin material constituting the ventilation member 20, a pore forming agent that forms the small pore structure 21 and the large pore structure 22, and an additive that is added as necessary.
- the material constituting the ventilation member 20 examples include polybutylene terephthalate (PBT), polybutylene naphthalate, polyethylene, polystyrene, acrylonitrile-styrene copolymer resin (AS resin), and acrylonitrile-butadiene-styrene copolymer resin (ABS resin). ), Thermoplastic resins such as polypropylene, polycarbonate, and polyacetal can be used. Among these, it is preferable to use PBT capable of obtaining the ventilation member 20 having high strength and heat resistance.
- pore forming agent As the pore forming agent, it is possible to use a material that melts at a molding temperature in a molding process described later and is soluble in a solvent used in an extraction process described later.
- pore forming agents include polyhydric alcohols having about 2 to 5 carbon atoms, saccharides, water-soluble alkali metal salts, water-soluble resins, and the like.
- the polyhydric alcohol having about 2 to 5 carbon atoms include pentaerythritol, L-erythritol, D-erythritol, meso-erythritol, piconal, glycerin, ethylene glycol, propylene glycol and the like.
- Examples of the saccharide include monosaccharides or disaccharides such as glucose, fructose, sucrose, and maltose.
- Examples of the water-soluble alkali metal salt include potassium chloride, sodium chloride, sodium sulfate, potassium sulfate, sodium nitrate, and potassium nitrate.
- Examples of the water-soluble resin include polyvinyl alcohol, polyethylene glycol, and polypropylene glycol.
- the dispersed state, melted state, and the like of the pore-forming agent in the resin material are different. For this reason, by extracting the pore forming agent from the resin material by an extraction step described later, pores having different sizes are formed in the resin material depending on the material selected as the pore forming agent and the resin material.
- the pore forming agent in order to form the small hole diameter structure 21 and the large hole diameter structure 22 having different hole diameters in the ventilation member 20, at least two or more kinds of materials as described above are selected.
- pore forming agents it is preferable to use at least one selected from ethylene glycol, propylene glycol, glycerin, polyethylene glycol, and polypropylene glycol in combination with pentaerythritol.
- ethylene glycol, propylene glycol, glycerin, polyethylene glycol, and polypropylene glycol in combination with pentaerythritol.
- these materials can be dissolved in water, water can be used as a solvent in the extraction step described later. Thereby, compared with the case where an organic solvent is used as a solvent, for example, cleaning and post-processing are facilitated, and the manufacturing process of the ventilation member 20 can be simplified.
- the mixing step In the mixing step, the resin material constituting the ventilation member 20, the pore forming agent, and the additive added as necessary are mixed using a known mixer.
- the resin material and the pore-forming agent may be mixed without melting the resin material and the pore-forming agent, or the resin material and the pore-forming agent are mixed (kneaded).
- a tumbler mixer, a Henschel mixer, an oven roll, a kneader, an intensive mixer, or the like can be used as a mixer.
- the mixing ratio of the resin material and the pore forming agent varies depending on the resin material and the material used as the pore forming agent, but PBT is used as the resin material, and ethylene glycol, propylene glycol, glycerin, polyethylene glycol and polypropylene are used as the pore forming agent.
- PBT is used as the resin material
- ethylene glycol, propylene glycol, glycerin, polyethylene glycol and polypropylene are used as the pore forming agent.
- ethylene glycol, propylene glycol, glycerin, polyethylene glycol and polypropylene glycol is preferable to mix at least one selected from 0.25 to 3.00 parts by weight.
- the porosity of the finally obtained ventilation member 20 becomes low, and the open-cell structure in which the small-pore structure 21 and the large-pore structure 22 communicate with each other in the ventilation member 20. Less. In this case, it is difficult for water vapor to pass through the ventilation member 20, and when the ventilation member 20 is applied to the vehicle lamp 1, it is difficult to eliminate the fogging of the lens 3. Moreover, when there is too much mixing amount of the pore formation agent with respect to a resin material, the porosity of the ventilation member 20 may become high too much, and there exists a possibility that the intensity
- the molding step the mixed product obtained in the mixing step is molded into a desired shape to obtain a molded body.
- the molding method is not particularly limited, and for example, methods such as compression molding, transfer molding, injection molding, extrusion molding, and casting can be used.
- the molding temperature is set to a temperature at which the resin material can be molded, and at least a part of the pore forming agent is melted and the melted part communicates.
- the resin material when PBT is selected as the resin material, and at least one selected from ethylene glycol, propylene glycol, glycerin, polyethylene glycol and polypropylene glycol and pentaerythritol are selected as the pore forming agent,
- the mixed product obtained in the mixing step is extruded by an extruder, and then cooled and cut into pellets.
- the pelletized mixed product is injection molded into a desired shape using a known injection molding machine to obtain a molded product.
- the solvent used in the extraction process varies depending on the resin material and pore forming agent.
- water, glycol, glycol ether, high molecular weight alcohol, fatty acid, fatty acid ester, glycol ester, mineral oil, petroleum, alcohol ethoxylate, polyoxyethylene examples thereof include esters, glycerol, glycerol esters and the like.
- water should be selected as the solvent used for extraction. Is preferred.
- the extraction step it is preferable to extract the pore forming agent in a state where the above-mentioned solvent is heated to, for example, about 60 ° C. to 100 ° C.
- the solvent By heating the solvent, extraction of the pore forming agent into the solvent can be promoted, and the pore forming agent is prevented from remaining in the resin material.
- Water / oil repellency treatment As described above, when a water / oil-repellent film is provided on the ventilation member 20, subsequently, the water / oil-repellency treatment is performed on the ventilation member 20 obtained in the extraction step.
- the method of the water / oil repellency treatment is not particularly limited.
- the ventilation member 20 in which the small pore diameter structure 21 and the large pore diameter structure 22 are formed is immersed in the water / oil repellency treatment agent and then dried. Examples thereof include a method and a method of applying a water / oil repellent treatment agent to the ventilation member 20 and then drying.
- the water / oil repellent treatment agent for example, a spray method, a spin coating method, a doping method, a roll coater method, or the like can be used.
- the water / oil repellent treatment agent is not particularly limited, and as described above, a silicone-based or fluorine-based water / oil repellent treatment agent can be used.
- the thickness t1 of the ventilation member 20 is 1 mm or more when the ventilation member 20 is produced only by the above-described extraction method, although it varies depending on the type of resin material and pore forming agent used as the material of the ventilation member 20. Is preferred.
- the ventilation member 20 having a thickness t1 of less than 1 mm is formed by the extraction method, the open-cell structure of the small hole diameter structure 21 and the large hole diameter structure 22 is liable to collapse on the surface of the ventilation member 20, and the vehicle lamp 1 can be There is a risk that water vapor will be insufficiently discharged to the outside.
- the ventilation member 20 having a thickness of less than 1 mm is formed while suppressing the exhaustion of water vapor. can do.
- the method of manufacturing the ventilation member 20 of the present embodiment is not limited to the above-described method.
- the small pore structure 21 and the large pore structure 22 are formed by mixing a foaming agent with a resin material and foaming. Also good.
- the type of foaming agent for example, by adjusting the type of foaming agent, the amount of foaming agent added, foaming time, foaming temperature, and the like, the small pore structure 21 and the large pore structure 22 having a structure communicating with each other can be formed.
- the foam is broken by mechanically deforming the foam, You may form the ventilation member 20 which has the open-cell structure where the large hole diameter structure 22 connected.
- Example 1 By using PBT as the resin material, pentaerythritol and glycerin as the pore forming agent, and using the extraction method described above, a cylindrical ventilation member 20 having a ventilation portion area (planar area) of 300 mm 2 and a thickness of 1 mm was produced.
- the obtained ventilation member 20 has a continuous bubble structure in which the small hole diameter structure 21 and the large hole diameter structure 22 communicate with each other, the hole diameter (first hole diameter D1) of the small hole diameter structure 21 is 5 ⁇ m, and the large hole diameter structure No. 22 hole diameter (second hole diameter D2) was 30 ⁇ m.
- Example 2 A ventilation member 20 was produced in the same manner as in Example 1 except that the thickness of the ventilation member 20 was 2 mm (Example 2), 5 mm (Example 3), and 10 mm (Example 4).
- Comparative Example 2 A high molecular weight polyethylene powder is filled in an aluminum mold, heated until the mold surface temperature reaches 175 ° C., cooled to room temperature, and a cylindrical polyethylene porous body having a vent area of 300 mm 2 and a thickness of 1 mm. Got.
- the obtained polyethylene porous body had a plurality of pores having a substantially uniform pore diameter, and the pore diameter was 10 ⁇ m.
- Comparative Example 3 A polyethylene porous body was obtained in the same manner as in Comparative Example 2 except that the thickness was 2 mm.
- the ventilation members obtained in Examples 1 to 4 and Comparative Examples 1 to 3 were attached to the vehicular lamp 1 that was conditioned as follows, and an evaluation test for cloudiness was performed.
- the vehicle lamp 1 a medium-size car headlamp having an internal volume of 6900 cc (Hyundai 2011 Genesis Coupe headlamp) was used. (Humidity control) First, the vehicular lamp 1 having all the openings such as the ventilation openings 9 opened was left for 2 hours under high temperature drying conditions (temperature: 80 ⁇ 2 ° C., relative humidity (RH): 10%). Subsequently, the vehicle lamp 1 was left for 1 hour under normal temperature and normal pressure conditions (temperature: 15 ° C.
- the vehicle lamp 1 is left under humidity control conditions (temperature: 38 ° C., RH: 70%) for 1 hour with the ventilation opening 9 and the like opened, and the humidity inside the housing of the vehicle lamp 1 is reduced. It was adjusted.
- the ventilation member 20 obtained in Examples 1 to 4 and Comparative Examples 1 to 3 is attached to the ventilation opening 9 of the vehicular lamp 1 immediately after the humidity control is performed through a socket (supporting member 11). The other openings other than the ventilation opening 9 were closed. The vehicle lamp 1 was turned on for 20 minutes and then turned off.
- the time until the fogging of the lens 3 is eliminated is 3 minutes or less.
- the ventilation member 20 of Examples 1 to 4 can achieve good cloudiness.
- water liquid water did not enter the housing 8.
- the ventilation member 20 of Examples 1 to 4 can achieve good cloudiness while suppressing the intrusion of liquid water into the housing 8.
- SYMBOLS 1 Vehicle lamp, 2 ... Housing, 3 ... Lens, 8 ... Inside housing, 9 ... Vent opening, 10 ... Ventilation unit, 20 ... Ventilation member, 21 ... Small hole diameter structure, 22 ... Large hole diameter structure
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Abstract
Description
本発明は、筐体内から筐体外部への水蒸気の排出を促進可能な通気部材および通気装置を提供することを目的とする。
ここで、前記小孔径構造21は、孔径D1が0.5μm以上50μm以下であることを特徴とすることができる。
また、前記大孔径構造22は、孔径D2が5μm以上100μm以下であることを特徴とすることができる。
ここで、前記通気部材20の厚みt1は、10mm以下であることを特徴とすることができる。
また、前記通気部材20の厚みt1は、1mm以上であることを特徴とすることができる。
さらに、前記通気部材20は凹凸成形品であり、当該凹凸により表面積を増加させ、水蒸気の透過面積を広げることを特徴とすることができる。
〔車両用ランプの全体構成〕
図1は、本実施の形態が適用される車両用ランプ1の全体構成を示した図である。
本実施の形態が適用される車両用ランプ1は、例えば自動車用に代表される各種車両のヘッドランプ、リアランプ、ブレーキランプ、フォグランプ、方向指示ランプ、走行ランプ、駐車ランプ等として用いられる。図1では、これらランプ類の一例を示している。
続いて、本実施の形態の通気ユニット10について説明する。図2(a)~図2(b)は、本実施の形態が適用される通気ユニット10の構成を説明するための図であって、図2(a)は、通気ユニット10の斜視図であり、図2(b)は、通気ユニット10を、通気ユニット10における通気方向に沿って切った断面図である。
図1および図2(a)~図2(b)に示すように、本実施の形態の通気ユニット10は、車両用ランプ1の筐体内8と車両用ランプ1の外部との間の通気を行う通気部材20と、車両用ランプ1の通気開口9を形成する凸部9aに取り付けられ、通気部材20を支持する支持部材11とを有している。
また、支持部材11は、貫通孔の内周にて通気部材20を支持している。言い換えると、本実施の形態の支持部材11は、通気部材20により通気経路が塞がれた状態となっている。なお、支持部材11に対する通気部材20の取り付け方法は、特に限定されるものではなく、例えば溶着法やスナップフィット等の嵌め込み法により取り付けてもよく、粘着テープや接着剤等により取り付けてもよい。
なお、支持部材11の内径が過度に小さい場合には、通気ユニット10における通気面積が小さくなるため、車両用ランプ1の筐体内8から外部へ水蒸気が透過しにくくなり、車両用ランプ1の曇りを抑制する効果が小さくなりやすい。
本実施の形態の通気部材20は、図2(a)等に示すように、全体として例えば円盤状の形状を有している。すなわち、本実施の形態の通気部材20は、対向する2つの円形状の平面20A、20B、および平面20Aと平面20Bとを接続する側面を有している。
そして、通気部材20は、通気ユニット10が車両用ランプ1の通気開口9に取り付けられた状態で、一方の平面(この例では、平面20A)が車両用ランプ1の筐体内8に対向し、他方の平面(この例では、平面20B)が車両用ランプ1の外部に対向するようになる。なお、後述するように、通気部材20の形状は、図2(a)に示した円盤状の形状に限られるものではない。
そして、通気部材20は、車両用ランプ1の筐体内8と車両用ランプ1の外部との間で通気を行うとともに、車両用ランプ1の筐体内8に塵埃等の異物や液体の水(液水)等が入り込むことを抑制している。また、通気部材20は、筐体内8の水蒸気を透過させて車両用ランプ1の外部に排出することで、レンズ3の曇りの発生を抑制している。
これらのなかでも、通気部材20の強度や耐熱性等の観点から、PBTを用いることが好ましい。
図3に示すように、本実施の形態の通気部材20は、孔径の異なる孔(小孔21a、大孔22a)が複数形成された多孔質体からなる。そして、通気部材20は、複数の小孔径構造21と、小孔径構造21と比較して径が大きい複数の大孔径構造22とを有している。
具体的には、小孔径構造21は、通気部材20に形成された小孔21aを囲む壁面21bにより構成され、大孔径構造22は、通気部材20に形成された大孔22aを囲む壁面22bにより構成される。
ここで、小孔径構造21と大孔径構造22が連通している状態とは、小孔径構造21と大孔径構造22との間で、水蒸気や空気等が流通可能な状態である。言い換えると、小孔径構造21により囲まれる小孔21aと、大孔径構造22により囲まれる大孔22aとが、一続きの空間となっている状態である。
また、通気部材20において、図3に示すように、1の小孔径構造21に対して複数の大孔径構造22が連通していてもよく、1の大孔径構造22に対して複数の小孔径構造21が連通していてもよい。
さらに、通気部材20において、複数の小孔径構造21同士が連通している部分が存在してもよく、複数の大孔径構造22同士が連通している部分が存在してもよい。
これにより、通気ユニット10が車両用ランプ1に取り付けられた状態において、通気部材20を介して空気や水蒸気が、筐体内8と車両用ランプ1の外部とを移動できるようになっている。
通気部材20の厚みを1mm以上とすることで、小孔径構造21と大孔径構造22とが連通した連泡構造を十分に長く確保することが可能になり、筐体内8から車両用ランプ1の外部への水蒸気の排出を促進することが可能になる。
通気部材20の厚みt1が10mmよりも厚い場合、筐体内8から車両用ランプ1(図1参照)の外部までの距離が長くなるため、車両用ランプ1の外部への水蒸気の排出に要する時間が長くなる。この場合、車両用ランプ1のレンズ3(図1参照)の曇りが晴れるまでの時間が長くなりやすい。
ただし、通気部材20の厚みt1は、成形品としての強度を保つことができ、水蒸気を透過して車両用ランプ1等の曇りを抑制し、曇りが発生した場合に迅速に曇りを解消することができる厚みであれば、上記範囲に限定されるものではない。
第1孔径D1は、第2孔径D2より小さく、且つ0.5μm以上50μm以下の範囲であることが好ましい。第1孔径D1が0.5μm未満である場合、小孔径構造21により形成される流路において水蒸気が透過しにくくなり、車両用ランプ1の曇りを迅速に解消することが難しくなる。第1孔径D1が50μmよりも大きい場合、塵埃等の異物が通気部材20を通過して車両用ランプ1の筐体内8に侵入するおそれがある。
また、第2孔径D2は、第1孔径D1よりも大きく、且つ5μm以上100μm以下の範囲であることが好ましい。第2孔径D2が5μm未満である場合、大孔径構造22による水蒸気の排出を促進する効果が不十分になる場合がある。第2孔径D2が100μm以上である場合、通気部材20の強度が低下するおそれがある。
第2孔径D2が第1孔径D1の2倍未満の大きさであると、小孔径構造21と大孔径構造22との孔径の差が小さいため、小孔径構造21と大孔径構造22との連泡構造による後述するポンプ効果が不十分となり、水蒸気の排出が促進されにくくなるおそれがある。
すなわち、通気部材20の断面の走査型電子顕微鏡(Scanning Electron Microscope;SEM)写真を撮影し、SEM写真における所定の範囲(例えば1辺を200μmとする正方形の範囲)に存在する孔の面積を市販の画像処理ソフト等により解析する。なお、複数の孔が互いに連通している場合、それぞれの孔が連通していないものと仮定して、孔の面積を解析する。そして、解析した孔の面積に基いて、それぞれの孔の円換算直径およびその分布(個数分布)を求める。本実施の形態では、通気部材20に形成される孔として、小孔径構造21に対応する小孔21aと大孔径構造22に対応する大孔22aとが存在するため、得られる円換算直径の分布は、概ね2つのピークを有するものとなる。本実施の形態では、得られた円換算直径の分布におけるピーク値のうち、小さい方の値を第1孔径D1、大きい方の値を第2孔径D2とすることができる。
また、車両用ランプ1の筐体2を密閉すると、車両用ランプ1のバルブ4等の発熱により筐体内8が高温になり筐体内8の空気が膨張した場合に、筐体2が破損するおそれがある。
続いて、本実施の形態の通気部材20の作用について具体的に説明する。
通気開口9に通気ユニット10(通気部材20)を取り付けた車両用ランプ1において、筐体内8の湿度が車両用ランプ1の外部と比較して高くなった場合、筐体内8と車両用ランプ1の外部との湿度の差を解消するために、水蒸気が、筐体内8から車両用ランプ1の外部に向かって通気部材20内を移動する。より具体的には、水蒸気が、通気部材20において小孔径構造21と大孔径構造22とにより形成される流路を、筐体内8から車両用ランプ1の外部に向かって移動する。
この結果、小孔径構造21と大孔径構造22とが連通することで水蒸気の流路が形成される本実施の形態の通気部材20では、例えば孔径が略均一な複数の孔により水蒸気の流路が形成される場合と比較して、通気部材20における水蒸気の透過が促進される。
そして、通気部材20を筐体内8から車両用ランプ1の外部への水蒸気の排出を迅速に行うことが可能になり、車両用ランプ1のレンズ3に曇りが生じることを抑制できる。また、レンズ3に曇りが発生した場合であっても、迅速にレンズ3の曇りを解消することが可能になる。
なお、通気部材20は、小孔径構造21と大孔径構造22とが連通した連泡構造を有する成形体であれば、その形状は図2に示した円盤形状に限られず、通気部材20を取り付ける車両用ランプ1の形状等に応じて適宜選択することができる。例えば、通気部材20の形状を、四角柱等の多角柱形状や球形状等としてもよい。また、通気部材20を支持する支持部材11の形状についても、図2に示した円筒形状に限られず、通気部材20の形状や車両用ランプ1の形状に応じて適宜選択することができる。さらに、通気部材20は、支持部材11等を介さずに、直接、通気開口9に取り付けてもよい。
図4(a)~図4(b)は、通気部材20の他の形態を示した図であって、図4(a)は、通気部材20の斜視図であり、図4(b)は、図4(a)におけるIVB-IVB断面図である。
本実施の形態の通気部材20は、取り付け部31と山型突起部32とを含む通気部材20の全体が、上述した小孔径構造21(図3参照)および大孔径構造22(図3参照)が連通した連泡構造を有する多孔質体から構成されている。
また、本実施の形態の通気部材20は、山型突起部32が形成されることで、表面(図4(b)における上側)および裏面(図4(b)における下側)の双方が、凹凸面となっており、山型突起部32が形成されない場合と比較して、表面積が大きくなっている。
なお、通気部材20の通気開口9への取り付け方法としては、特に限定されず、例えば溶着法やスナップフィット等の嵌め込み法により取り付けてもよく、粘着テープや接着剤等により取り付けてもよい。
続いて、通気部材20の製造方法について説明する。なお、以下では、通気部材20の製造方法の一例として、通気部材20を、所謂「抽出法」により製造する方法について説明する。
通気部材20の抽出法による製造方法は、通気部材20を構成する樹脂材料、小孔径構造21および大孔径構造22を形成する気孔形成剤、必要に応じて添加される添加剤を混合する混合工程と、混合工程にて得られた混合生成物を所望の形状に成形加工して成形体を得る成形工程と、成形工程で得られた成形体から気孔形成剤を抽出して小孔径構造21および大孔径構造22を形成し通気部材20を得る抽出工程と、を含む。
通気部材20を構成する材料としては、例えば、ポリブチレンテレフタレート(PBT)、ポリブチレンナフタレート、ポリエチレン、ポリスチレン、アクリロニトリル-スチレン共重合樹脂(AS樹脂)、アクリロニトリル-ブタジエン-スチレン共重合樹脂(ABS樹脂)、ポリプロピレン、ポリカーボネート、ポリアセタール等の熱可塑性樹脂を用いることができる。
これらの中でも、強度や耐熱性が高い通気部材20を得ることができるPBTを用いることが好ましい。
気孔形成剤としては、後述する成形工程における成形温度で溶融し、且つ後述する抽出工程で用いる溶媒に溶解可能な材料を使用することができる。このような気孔形成剤としては、炭素数2~5程度の多価アルコール、糖類、水溶性アルカリ金属塩、水溶性樹脂等が挙げられる。炭素数2~5程度の多価アルコールとしては、例えば、ペンタエリスリトール、L-エリスリトール、D-エリスリトール、meso-エリスリトール、ピコナール、グリセリン、エチレングリコール、プロピレングリコール等が挙げられる。糖類としては、例えば、ブドウ糖、果糖、ショ糖、麦芽糖等の単糖もしくは二糖が挙げられる。水溶性アルカリ金属塩としては、例えば、塩化カリウム、塩化ナトリウム、硫酸ナトリウム、硫酸カリウム、硝酸ナトリウム、硝酸カリウム等が挙げられる。また、水溶性樹脂としては、例えば、ポリビニルアルコール、ポリエチレングリコール、ポリプロピレングリコール等が挙げられる。
本実施の形態では、通気部材20に、孔径の異なる小孔径構造21と大孔径構造22とを形成するために、上述したような気孔形成剤のうち少なくとも2種以上の材料を選択する。
これらの材料を選択することで、通気部材20の全域に亘って、小孔径構造21と大孔径構造22とが連通した連泡構造を一様に形成することができる。言い換えると、通気部材20において、気孔率のムラが生じることが抑制される。
また、これらの材料は水に溶解可能なため、後述する抽出工程において、溶媒として水を用いることができる。これにより、例えば溶媒として有機溶媒を使用する場合と比較して、洗浄や後処理が容易になり、通気部材20の製造工程を簡素化することができる。
混合工程では、通気部材20を構成する樹脂材料、気孔形成剤および必要に応じて添加する添加剤を、公知の混合機を用いて混合する。なお、混合工程では、樹脂材料および気孔形成剤として選択する材料により、樹脂材料および気孔形成剤を溶融させない状態で混合してもよく、樹脂材料と気孔形成剤とを溶融した状態で混合(混練)してもよい。
混合工程では、混合機として、例えば、タンブラー混合機、ヘンシェルミキサー、オーブンロール、ニーダー、インテンシブミキサー等を用いることができる。
また、樹脂材料に対する気孔形成剤の混合量が過度に多い場合、通気部材20の気孔率が過度に高くなり、通気部材20の強度が低くなるおそれがある。
成形工程では、混合工程で得られた混合生成物を、所望の形状に成形加工して成形体を得る。成形方法は、特に限定されず、例えば、圧縮成形、トランスファ成形、射出成形、押出成形、注型等の方法を用いることができる。
また、本実施の形態の成形工程では、成形温度は、樹脂材料を成形でき、且つ気孔形成剤の少なくとも一部が溶融して溶融部分が連通する温度に設定する。
抽出工程では、上述した樹脂材料は溶解しないが、気孔形成剤は溶解する溶媒に成形工程で得られた成形品を浸漬し、気孔形成剤を溶媒に溶解させ、溶解せずに残存した樹脂材料中に互いに連通した小孔径構造21および大孔径構造22を形成する。そして、溶媒を乾燥機等で乾燥させることで、小孔径構造21および大孔径構造22を有する通気部材20を得る。
上述したように、気孔形成剤として、エチレングリコール、プロピレングリコール、グリセリン、ポリエチレングリコール及びポリプロピレングリコールから選択される少なくとも一種と、ペンタエリスリトールとを選択した場合、抽出に用いる溶媒としては水を選択することが好ましい。
なお、上述したように通気部材20に撥水・撥油性の被膜を設ける場合、続いて、抽出工程で得られた通気部材20に対して、撥水・撥油性処理を行う。
撥水・撥油性処理の方法としては、特に限定されず、例えば、小孔径構造21および大孔径構造22が形成された通気部材20を、撥水・撥油処理剤に浸漬し、その後乾燥する方法や、通気部材20に撥水・撥油処理剤を塗布し、その後乾燥する方法等が挙げられる。撥水・撥油処理剤を塗布する方法としては、例えば、スプレー法、スピンコート法、ドッピング法、ロールコータ法等を用いることができる。
また、撥水・撥油処理剤としては特に限定されず、上述したように、シリコーン系やフッ素系の撥水・撥油処理剤を用いることができる。
なお、この場合、例えば抽出法により作成した通気部材20の表面を磨いたり切断したりすることで、水蒸気の排出が不十分になることを抑制しながら、厚みが1mm未満の通気部材20を形成することができる。
また、小孔径構造21と大孔径構造22とが連通していない独立気泡型の発泡体を得た後、例えばこの発泡体に機械的変形を加えることで気泡を破壊し、小孔径構造21と大孔径構造22とが連通した連泡構造を有する通気部材20を形成してもよい。
(実施例1)
樹脂材料としてPBTを用い、気孔形成剤としてペンタエリスリトールおよびグリセリンを用い、上述した抽出法により、通気部面積(平面面積)が300mm2、厚み1mmの円柱形状の通気部材20を作製した。
得られた通気部材20は、小孔径構造21と大孔径構造22とが連通した連泡構造を有しており、小孔径構造21の孔径(第1孔径D1)が5μmであり、大孔径構造22の孔径(第2孔径D2)が30μmであった。
通気部材20の厚みを、2mm(実施例2)、5mm(実施例3)、10mm(実施例4)とした以外は実施例1と同様にして、通気部材20を作製した。
ポリテトラフルオロエチレン(PTFE)フィルムを延伸することにより、厚み0.05mmのPTFE延伸フィルムを得た。得られたPTFE延伸フィルムは、孔径が略均一な複数の孔が形成されており、孔径は10μmであった。
高分子量ポリエチレン粉末をアルミニウム製の金型に充填し、金型の表面温度が175℃になるまで加熱した後、室温まで冷却し、通気部面積が300mm2、厚み1mmの円柱形状のポリエチレン多孔体を得た。得られたポリエチレン多孔体は、孔径が略均一な複数の孔が形成されており、孔径は10μmであった。
厚みを2mmとした以外は比較例2と同様にして、ポリエチレン多孔体を得た。
(調湿)
まず、通気開口9等の全ての開口を開放状態とした車両用ランプ1を、高温乾燥条件(温度:80±2℃、相対湿度(RH):10%)で2時間放置した。続いて、通気開口9等を開放状態としたまま、車両用ランプ1を、常温常圧条件(温度:15℃~35℃、RH:45%~75%)で1時間放置した。
その後、通気開口9等を開放状態としたまま、車両用ランプ1を、調湿条件(温度:38℃、RH:70%)で1時間放置し、車両用ランプ1の筐体内8の湿度を調整した。
上記調湿を行った直後の車両用ランプ1の通気開口9に対し、実施例1~4および比較例1~3で得られた通気部材20を、ソケット(支持部材11)を介して取り付けるとともに、通気開口9以外の他の開口を閉じた。そして、車両用ランプ1を20分間点灯した後、消灯した。
表1に、実施例1~実施例4および比較例1~比較例3の試験結果を示す。
また、実施例1~実施例4の通気部材20では、筐体内8への水(液水)の侵入が見られなかった。すなわち、実施例1~実施例4の通気部材20では、筐体内8への液水の侵入を抑制しながら、良好な曇り晴れ性を実現できることが確認された。
これに対し、複数の孔の孔径が略均一な多孔質体からなる比較例1~比較例3の通気部材では、筐体内8へ液水の侵入は抑制できるものの、レンズ3の曇りが解消するまでの時間が8分以上かかっており、実施例1~実施例4の通気部材20と比較してレンズ3の曇りが解消するまでに長い時間を要することが確認された。
Claims (8)
- 閉鎖されたランプ筐体内の水蒸気を排出する多孔質体の通気部材であって、
液水および汚染物質の前記ランプ筐体内への侵入を阻止するとともに、当該ランプ筐体内から外部へ水蒸気を排出するための流路を形成する小孔径構造と、
前記小孔径構造よりも径が大きく当該小孔径構造と連通して設けられる大孔径構造と
を有する通気部材。 - 前記小孔径構造は、孔径が0.5μm以上50μm以下であることを特徴とする請求項1記載の通気部材。
- 前記大孔径構造は、孔径が5μm以上100μm以下であることを特徴とする請求項1記載の通気部材。
- 閉鎖された筐体内と外部との間の通気を行う多孔質体の通気部材であって、
液水および汚染物質の前記筐体内への侵入を阻止するとともに、当該筐体内から外部へ水蒸気を透過させる小孔径構造と、
前記小孔径構造よりも径が大きい大孔径構造と
を備え、形状として自立性を有する厚みを有する成形品として形成される通気部材。 - 前記通気部材の厚みは、10mm以下であることを特徴とする請求項4記載の通気部材。
- 前記通気部材の厚みは、1mm以上であることを特徴とする請求項5記載の通気部材。
- 前記通気部材は凹凸成形品であり、当該凹凸により表面積を増加させ、水蒸気の透過面積を広げることを特徴とする請求項5または6記載の通気部材。
- 閉鎖されたランプ内の水蒸気を排出するための通気装置であって、
少なくとも一つの通気開口を有して閉鎖されたランプ筐体と、
前記通気開口に設けられる通気部材とを備え、
前記通気部材は、
孔径が0.5μm以上50μm以下の小孔径構造と、
前記小孔径構造に連通して設けられ、当該小孔径構造よりも径の大きい大孔径構造と
を有することを特徴とする通気装置。
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CN201480078192.6A CN106461177A (zh) | 2014-04-23 | 2014-12-15 | 通气部件及通气装置 |
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JP6590869B2 (ja) * | 2017-06-21 | 2019-10-16 | 矢崎総業株式会社 | 電子部品ユニット、ワイヤハーネス、及び、通気部防水構造 |
JP2019094246A (ja) * | 2017-11-27 | 2019-06-20 | 地方独立行政法人山口県産業技術センター | 多孔体 |
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EP3135986A4 (en) | 2018-01-03 |
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